Interactive feedback system for powered surgical instruments

ABSTRACT

A surgical instrument includes an end effector having first and second jaws that cooperate to capture tissue therebetween, a movable firing member to cut the tissue, an actuator actuatable between various settings that define various output values of a characteristic of motion of the firing member, and a real-time feedback system. The real-time feedback system includes a sensor to assess a parameter of the end effector, a zone indicator adjustable between various positions inside and outside a desired zone, and a circuit to receive the sensor input from the sensor, the sensor input defining a measurement of a parameter of the end effector, and select one of various positions based upon the measurement of the parameter of the end effector, the selected position representing a status of a current output value of the characteristic of motion of the firing member, and adjust the zone indicator to the selected position.

BACKGROUND

The present disclosure relates to surgical instruments and, in variouscircumstances, to surgical stapling and cutting instruments and staplecartridges therefor that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present disclosure, and the manner ofattaining them, will become more apparent and the present disclosurewill be better understood by reference to the following description ofthe present disclosure taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a surgical instrument that has aninterchangeable shaft assembly operably coupled thereto;

FIG. 2 is an exploded assembly view of the interchangeable shaftassembly and surgical instrument of FIG. 1;

FIG. 3 is another exploded assembly view showing portions of theinterchangeable shaft assembly and surgical instrument of FIGS. 1 and 2;

FIG. 4 is an exploded assembly view of a portion of the surgicalinstrument of FIGS. 1-3;

FIG. 5 is a cross-sectional side view of a portion of the surgicalinstrument of FIG. 4 with the firing trigger in a fully actuatedposition;

FIG. 6 is another cross-sectional view of a portion of the surgicalinstrument of FIG. 5 with the firing trigger in an unactuated position;

FIG. 7 is an exploded assembly view of one form of an interchangeableshaft assembly;

FIG. 8 is another exploded assembly view of portions of theinterchangeable shaft assembly of FIG. 7;

FIG. 9 is another exploded assembly view of portions of theinterchangeable shaft assembly of FIGS. 7 and 8;

FIG. 10 is a cross-sectional view of a portion of the interchangeableshaft assembly of FIGS. 7-9;

FIG. 11 is a perspective view of a portion of the shaft assembly ofFIGS. 7-10 with the switch drum omitted for clarity;

FIG. 12 is another perspective view of the portion of theinterchangeable shaft assembly of FIG. 11 with the switch drum mountedthereon;

FIG. 13 is a perspective view of a portion of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anunactuated position;

FIG. 14 is a right side elevational view of the interchangeable shaftassembly and surgical instrument of FIG. 13;

FIG. 15 is a left side elevational view of the interchangeable shaftassembly and surgical instrument of FIGS. 13 and 14;

FIG. 16 is a perspective view of a portion of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anactuated position and a firing trigger thereof in an unactuatedposition;

FIG. 17 is a right side elevational view of the interchangeable shaftassembly and surgical instrument of FIG. 16;

FIG. 18 is a left side elevational view of the interchangeable shaftassembly and surgical instrument of FIGS. 16 and 17;

FIG. 18A is a right side elevational view of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anactuated position and the firing trigger thereof in an actuatedposition;

FIG. 19 is a schematic of a system for powering down an electricalconnector of a surgical instrument handle when a shaft assembly is notcoupled thereto;

FIG. 20 is an exploded view of one aspect of an end effector of thesurgical instrument of FIG. 1;

FIGS. 21A-21B is a circuit diagram of the surgical instrument of FIG. 1spanning two drawings sheets;

FIG. 22 illustrates one instance of a power assembly comprising a usagecycle circuit configured to generate a usage cycle count of the batteryback;

FIG. 23 illustrates one aspect of a process for sequentially energizinga segmented circuit;

FIG. 24 illustrates one aspect of a power segment comprising a pluralityof daisy chained power converters;

FIG. 25 illustrates one aspect of a segmented circuit configured tomaximize power available for critical and/or power intense functions;

FIG. 26 illustrates one aspect of a power system comprising a pluralityof daisy chained power converters configured to be sequentiallyenergized;

FIG. 27 illustrates one aspect of a segmented circuit comprising anisolated control section;

FIG. 28, which is divided into FIGS. 28A and 28B, is a circuit diagramof the surgical instrument of FIG. 1;

FIG. 29 is a block diagram the surgical instrument of FIG. 1illustrating interfaces between the handle assembly 14 and the powerassembly and between the handle assembly 14 and the interchangeableshaft assembly;

FIG. 30 illustrates a perspective view of a surgical instrument inaccordance with one aspect;

FIG. 31 illustrates an exploded view of the end effector of the surgicalinstrument of FIG. 81in accordance with one aspect;

FIG. 32 illustrates a partial side view of a handle of the surgicalinstrument of FIG. 81 in accordance with one aspect;

FIG. 33 illustrates a cross-sectional view of an end effector of thesurgical instrument of FIG. 81 in accordance with one aspect;

FIG. 34 illustrates a logic diagram of a process in accordance with oneaspect;

FIG. 35 illustrates a logic diagram of a feedback system in accordancewith one aspect;

FIG. 36 illustrates a logic diagram of a feedback system in accordancewith one aspect;

FIG. 37 illustrates a feedback indicator of a feedback system inaccordance with one aspect;

FIG. 38 illustrates a feedback indicator of a feedback system inaccordance with one aspect;

FIG. 39 illustrates a feedback indicator of a feedback system inaccordance with one aspect;

FIG. 40 illustrates a feedback indicator of a feedback system inaccordance with one aspect;

FIG. 41 illustrates a feedback indicator of a feedback system inaccordance with one aspect;

FIG. 42 illustrates a feedback indicator of a feedback system inaccordance with one aspect;

FIG. 43 illustrates a feedback indicator of a feedback system inaccordance with one aspect;

FIG. 44 illustrates a feedback indicator of a feedback system inaccordance with one aspect; and

FIG. 45 illustrates a feedback indicator of a feedback system inaccordance with one aspect.

DESCRIPTION

Applicant of the present application owns the following patentapplications that were filed on even date herewith and which are eachherein incorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. ______, entitled POWERED SURGICAL    INSTRUMENT; Attorney Docket No. END7556USNP/140481;-   U.S. patent application Ser. No. ______, entitled MULTIPLE LEVEL    THRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL INSTRUMENTS;    Attorney Docket No. END7552USNP/140477;-   U.S. patent application Ser. No. ______, entitled ADAPTIVE TISSUE    COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR MULTIPLE TISSUE    TYPES; Attorney Docket No. END7557USNP/140482;-   U.S. patent application Ser. No. ______, entitled OVERLAID MULTI    SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE TISSUE    COMPRESSION; Attorney Docket No. END7562USNP/140487;-   U.S. patent application Ser. No. ______, entitled MONITORING SPEED    CONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED SURGICAL    INSTRUMENTS; Attorney Docket No. END7549USNP/140474;-   U.S. patent application Ser. No. ______, entitled TIME DEPENDENT    EVALUATION OF SENSOR DATA TO DETERMINE STABILITY, CREEP, AND    VISCOELASTIC ELEMENTS OF MEASURES; Attorney Docket No.    END7559USNP/140484;-   U.S. patent application Ser. No. ______, entitled CONTROL TECHNIQUES    AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH SELECT CONTROL    PROCESSING FROM HANDLE; Attorney Docket No. END7540USNP/140465;-   U.S. patent application Ser. No. ______, entitled SMART SENSORS WITH    LOCAL SIGNAL PROCESSING; Attorney Docket No. END7538USNP/140463;-   U.S. patent application Ser. No. ______, entitled SURGICAL    INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING; Attorney Docket    No. END7548USNP/140473;-   U.S. patent application Ser. No. ______, entitled SYSTEM FOR    DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICAL    STAPLER; Attorney Docket No. END7546USNP/140471; and-   U.S. patent application Ser. No. ______, entitled SIGNAL AND POWER    COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT; Attorney    Docket No. END7561USNP/140486.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL    INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION;-   U.S. patent application Ser. No. 14/633,546, entitled SURGICAL    APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER OF    THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND;-   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL    CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE    BATTERIES;-   U.S. patent application Ser. No. 14/633,566, entitled CHARGING    SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A BATTERY;-   U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FOR    MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED;-   U.S. patent application Ser. No. 14/633,542, entitled REINFORCED    BATTERY FOR A SURGICAL INSTRUMENT;-   U.S. patent application Ser. No. 14/633,548, entitled POWER ADAPTER    FOR A SURGICAL INSTRUMENT;-   U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE    SURGICAL INSTRUMENT HANDLE;-   U.S. patent application Ser. No. 14/633,541, entitled MODULAR    STAPLING ASSEMBLY; and-   U.S. patent application Ser. No. 14/633,562, entitled SURGICAL    APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 14/574,478, entitled SURGICAL    INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND    MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING;-   U.S. patent application Ser. No. 14/574,483, entitled SURGICAL    INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS;-   U.S. patent application Ser. No. 14/575,139, entitled DRIVE    ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;-   U.S. patent application Ser. No. 14/575,148, entitled LOCKING    ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE    SURGICAL END EFFECTORS;-   U.S. patent application Ser. No. 14/575,130, entitled SURGICAL    INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A    DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE;-   U.S. patent application Ser. No. 14/575,143, entitled SURGICAL    INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS;-   U.S. patent application Ser. No. 14/575,117, entitled SURGICAL    INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING BEAM    SUPPORT ARRANGEMENTS;-   U.S. patent application Ser. No. 14/575,154, entitled SURGICAL    INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING    BEAM SUPPORT ARRANGEMENTS;-   U.S. patent application Ser. No. 14/574,493, entitled SURGICAL    INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM; and-   U.S. patent application Ser. No. 14/574,500, entitled SURGICAL    INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLE    SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL    COMMUNICATION, now U.S. Patent Application Publication No.    2014/0246471;-   U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWERED    ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2014/0246472;-   U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL    SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2014/0249557;-   U.S. patent application Ser. No. 13/782,499, entitled    ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT, now    U.S. Patent Application Publication No. 2014/0246474;-   U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE    PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now U.S.    Patent Application Publication No. 2014/0246478;-   U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK    SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Patent    Application Publication No. 2014/0246477;-   U.S. patent application Ser. No. 13/782,481, entitled SENSOR    STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now U.S.    Patent Application Publication No. 2014/0246479;-   U.S. patent application Ser. No. 13/782,518, entitled CONTROL    METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS,    now U.S. Patent Application Publication No. 2014/0246475;-   U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWERED    SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM, now U.S.    Patent Application Publication No. 2014/0246473; and-   U.S. patent application Ser. No. 13/782,536, entitled SURGICAL    INSTRUMENT SOFT STOP, now U.S. Patent Application Publication No.    2014/0246476.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 13/803,097, entitled ARTICULATABLE    SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now U.S. Patent    Application Publication No. 2014/0263542;-   U.S. patent application Ser. No. 13/803,193, entitled CONTROL    ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now U.S.    Patent Application Publication No. 2014/0263537;-   U.S. patent application Ser. No. 13/803,053, entitled    INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT,    now U.S. Patent Application Publication No. 2014/0263564;-   U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLE    SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. Patent    Application Publication No. 2014/0263541;-   U.S. patent application Ser. No. 13/803,210, entitled SENSOR    ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL    INSTRUMENTS, now U.S. Patent Application Publication No.    2014/0263538;-   U.S. patent application Ser. No. 13/803,148, entitled MULTI-FUNCTION    MOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent Application    Publication No. 2014/0263554;-   U.S. patent application Ser. No. 13/803,066, entitled DRIVE SYSTEM    LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S.    Patent Application Publication No. 2014/0263565;-   U.S. patent application Ser. No. 13/803,117, entitled ARTICULATION    CONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S.    Patent Application Publication No. 2014/0263553;-   U.S. patent application Ser. No. 13/803,130, entitled DRIVE TRAIN    CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S.    Patent Application Publication No. 2014/0263543; and-   U.S. patent application Ser. No. 13/803,159, entitled METHOD AND    SYSTEM FOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent    Application Publication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

-   U.S. patent application Ser. No. 14/200,111, entitled CONTROL    SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent Application    Publication No. 2014/0263539.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 14/226,106, entitled POWER    MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS;-   U.S. patent application Ser. No. 14/226,099, entitled STERILIZATION    VERIFICATION CIRCUIT;-   U.S. patent application Ser. No. 14/226,094, entitled VERIFICATION    OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT;-   U.S. patent application Ser. No. 14/226,117, entitled POWER    MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP    CONTROL;-   U.S. patent application Ser. No. 14/226,075, entitled MODULAR    POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES;-   U.S. patent application Ser. No. 14/226,093, entitled FEEDBACK    ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS;-   U.S. patent application Ser. No. 14/226,116, entitled SURGICAL    INSTRUMENT UTILIZING SENSOR ADAPTATION;-   U.S. patent application Ser. No. 14/226,071, entitled SURGICAL    INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR;-   U.S. patent application Ser. No. 14/226,097, entitled SURGICAL    INSTRUMENT COMPRISING INTERACTIVE SYSTEMS;-   U.S. patent application Ser. No. 14/226,126, entitled INTERFACE    SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS;-   U.S. patent application Ser. No. 14/226,133, entitled MODULAR    SURGICAL INSTRUMENT SYSTEM;-   U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS AND    METHODS FOR CONTROLLING A SEGMENTED CIRCUIT;-   U.S. patent application Ser. No. 14/226,076, entitled POWER    MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE    PROTECTION;-   U.S. patent application Ser. No. 14/226,111, entitled SURGICAL    STAPLING INSTRUMENT SYSTEM; and-   U.S. patent application Ser. No. 14/226,125, entitled SURGICAL    INSTRUMENT COMPRISING A ROTATABLE SHAFT.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY AND    SENSORS FOR POWERED MEDICAL DEVICE;-   U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT WITH    INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION;-   U.S. patent application Ser. No. 14/478,908, entitled MONITORING    DEVICE DEGRADATION BASED ON COMPONENT EVALUATION;-   U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE    SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR    INTERPRETATION;-   U.S. patent application Ser. No. 14/479,110, entitled USE OF    POLARITY OF HALL MAGNET DETECTION TO DETECT MISLOADED CARTRIDGE;-   U.S. patent application Ser. No. 14/479,098, entitled SMART    CARTRIDGE WAKE UP OPERATION AND DATA RETENTION;-   U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE MOTOR    CONTROL FOR POWERED MEDICAL DEVICE; and-   U.S. patent application Ser. No. 14/479,108, entitled LOCAL DISPLAY    OF TISSUE PARAMETER STABILIZATION.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. 14/248,590, entitled MOTOR DRIVEN    SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now U.S.    Patent Application Publication No. 2014/0305987;-   U.S. patent application Ser. No. 14/248,581, entitled SURGICAL    INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED    FROM THE SAME ROTATABLE OUTPUT, now U.S. Patent Application    Publication No. 2014/0305989;-   U.S. patent application Ser. No. 14/248,595, entitled SURGICAL    INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE OPERATION OF    THE SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.    2014/0305988;-   U.S. patent application Ser. No. 14/248,588, entitled POWERED LINEAR    SURGICAL STAPLER, now U.S. Patent Application Publication No.    2014/0309666;-   U.S. patent application Ser. No. 14/248,591, entitled TRANSMISSION    ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. Patent Application    Publication No. 2014/0305991;-   U.S. patent application Ser. No. 14/248,584, entitled MODULAR MOTOR    DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING    ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS, now U.S.    Patent Application Publication No. 2014/0305994;-   U.S. patent application Ser. No. 14/248,587, entitled POWERED    SURGICAL STAPLER, now U.S. Patent Application Publication No.    2014/0309665;-   U.S. patent application Ser. No. 14/248,586, entitled DRIVE SYSTEM    DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. Patent    Application Publication No. 2014/0305990; and-   U.S. patent application Ser. No. 14/248,607, entitled MODULAR MOTOR    DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS, now    U.S. Patent Application Publication No. 2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   U.S. Provisional Patent Application Ser. No. 61/812,365, entitled    SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE    MOTOR;-   U.S. Provisional Patent Application Ser. No. 61/812,376, entitled    LINEAR CUTTER WITH POWER;-   U.S. Provisional Patent Application Ser. No. 61/812,382, entitled    LINEAR CUTTER WITH MOTOR AND PISTOL GRIP;-   U.S. Provisional Patent Application Ser. No. 61/812,385, entitled    SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS AND MOTOR    CONTROL; and-   U.S. Provisional Patent Application Ser. No. 61/812,372, entitled    SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE    MOTOR.

The present disclosure provides an overall understanding of theprinciples of the structure, function, manufacture, and use of thedevices and methods disclosed herein. One or more examples of theseaspects are illustrated in the accompanying drawings. Those of ordinaryskill in the art will understand that the devices and methodsspecifically described herein and illustrated in the accompanyingdrawings are non-limiting examples. The features illustrated ordescribed in connection with one example may be combined with thefeatures of other examples. Such modifications and variations areintended to be included within the scope of the present disclosure.

Reference throughout the specification to “various aspects,” “someaspects,” “one aspect,” or “an aspect”, or the like, means that aparticular feature, structure, or characteristic described in connectionwith the aspect is included in at least one aspect. Thus, appearances ofthe phrases “in various aspects,” “in some aspects,” “in one aspect”, or“in an aspect”, or the like, in places throughout the specification arenot necessarily all referring to the same aspect. Furthermore, theparticular features, structures, or characteristics may be combined inany suitable manner in one or more aspects. Thus, the particularfeatures, structures, or characteristics illustrated or described inconnection with one aspect may be combined, in whole or in part, withthe features structures, or characteristics of one or more other aspectswithout limitation. Such modifications and variations are intended to beincluded within the scope of the present disclosure.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical,” “horizontal,” “up,” and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various example devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, theperson of ordinary skill in the art will readily appreciate that thevarious methods and devices disclosed herein can be used in numeroussurgical procedures and applications including, for example, inconnection with open surgical procedures. As the present DetailedDescription proceeds, those of ordinary skill in the art will furtherappreciate that the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongated shaft of asurgical instrument can be advanced.

FIGS. 1-6 depict a motor-driven surgical cutting and fasteninginstrument 10 that may or may not be reused. In the illustratedexamples, the instrument 10 includes a housing 12 that comprises ahandle assembly 14 that is configured to be grasped, manipulated andactuated by the clinician. The housing 12 is configured for operableattachment to an interchangeable shaft assembly 200 that has a surgicalend effector 300 operably coupled thereto that is configured to performone or more surgical tasks or procedures. As the present DetailedDescription proceeds, it will be understood that the various unique andnovel arrangements of the various forms of interchangeable shaftassemblies disclosed herein also may be effectively employed inconnection with robotically-controlled surgical systems. Thus, the term“housing” also may encompass a housing or similar portion of a roboticsystem that houses or otherwise operably supports at least one drivesystem that is configured to generate and apply at least one controlmotion which could be used to actuate the interchangeable shaftassemblies disclosed herein and their respective equivalents. The term“frame” may refer to a portion of a handheld surgical instrument. Theterm “frame” also may represent a portion of a robotically controlledsurgical instrument and/or a portion of the robotic system that may beused to operably control a surgical instrument. For example, theinterchangeable shaft assemblies disclosed herein may be employed withvarious robotic systems, instruments, components and methods disclosedin U.S. patent application Ser. No. 13/118,241, entitled SURGICALSTAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, nowU.S. Patent Application Publication No. US 2012/0298719. U.S. patentapplication Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTSWITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. PatentApplication Publication No. US 2012/0298719, is incorporated byreference herein in its entirety.

The housing 12 depicted in FIGS. 1-3 is shown in connection with aninterchangeable shaft assembly 200 that includes an end effector 300that comprises a surgical cutting and fastening device that isconfigured to operably support a surgical staple cartridge 304 therein.The housing 12 may be configured for use in connection withinterchangeable shaft assemblies that include end effectors that areadapted to support different sizes and types of staple cartridges, havedifferent shaft lengths, sizes, and types, etc. In addition, the housing12 also may be effectively employed with a variety of otherinterchangeable shaft assemblies including those assemblies that areconfigured to apply other motions and forms of energy such as, forexample, radio frequency (RF) energy, ultrasonic energy and/or motion toend effector arrangements adapted for use in connection with varioussurgical applications and procedures. Furthermore, the end effectors,shaft assemblies, handles, surgical instruments, and/or surgicalinstrument systems can utilize any suitable fastener, or fasteners, tofasten tissue. For instance, a fastener cartridge comprising a pluralityof fasteners removably stored therein can be removably inserted intoand/or attached to the end effector of a shaft assembly.

FIG. 1 illustrates the surgical instrument 10 with an interchangeableshaft assembly 200 operably coupled thereto. FIGS. 2 and 3 illustrateattachment of the interchangeable shaft assembly 200 to the housing 12or handle assembly 14. As shown in FIG. 4, the handle assembly 14 maycomprise a pair of interconnectable handle housing segments 16 and 18that may be interconnected by screws, snap features, adhesive, etc. Inthe illustrated arrangement, the handle housing segments 16, 18cooperate to form a pistol grip portion 19 that can be gripped andmanipulated by the clinician. As will be discussed in further detailbelow, the handle assembly 14 operably supports a plurality of drivesystems therein that are configured to generate and apply variouscontrol motions to corresponding portions of the interchangeable shaftassembly that is operably attached thereto.

Referring now to FIG. 4, the handle assembly 14 may further include aframe 20 that operably supports a plurality of drive systems. Forexample, the frame 20 can operably support a “first” or closure drivesystem, generally designated as 30, which may be employed to applyclosing and opening motions to the interchangeable shaft assembly 200that is operably attached or coupled thereto. In at least one form, theclosure drive system 30 may include an actuator in the form of a closuretrigger 32 that is pivotally supported by the frame 20. Morespecifically, as illustrated in FIG. 4, the closure trigger 32 ispivotally coupled to the housing 14 by a pin 33. Such arrangementenables the closure trigger 32 to be manipulated by a clinician suchthat when the clinician grips the pistol grip portion 19 of the handleassembly 14, the closure trigger 32 may be easily pivoted from astarting or “unactuated” position to an “actuated” position and moreparticularly to a fully compressed or fully actuated position. Theclosure trigger 32 may be biased into the unactuated position by springor other biasing arrangement (not shown). In various forms, the closuredrive system 30 further includes a closure linkage assembly 34 that ispivotally coupled to the closure trigger 32. As shown in FIG. 4, theclosure linkage assembly 34 may include a first closure link 36 and asecond closure link 38 that are pivotally coupled to the closure trigger32 by a pin 35. The second closure link 38 also may be referred toherein as an “attachment member” and include a transverse attachment pin37.

Still referring to FIG. 4, it can be observed that the first closurelink 36 may have a locking wall or end 39 thereon that is configured tocooperate with a closure release assembly 60 that is pivotally coupledto the frame 20. In at least one form, the closure release assembly 60may comprise a release button assembly 62 that has a distally protrudinglocking pawl 64 formed thereon. The release button assembly 62 may bepivoted in a counterclockwise direction by a release spring (not shown).As the clinician depresses the closure trigger 32 from its unactuatedposition towards the pistol grip portion 19 of the handle assembly 14,the first closure link 36 pivots upward to a point wherein the lockingpawl 64 drops into retaining engagement with the locking wall 39 on thefirst closure link 36 thereby preventing the closure trigger 32 fromreturning to the unactuated position. See FIG. 18. Thus, the closurerelease assembly 60 serves to lock the closure trigger 32 in the fullyactuated position. When the clinician desires to unlock the closuretrigger 32 to permit it to be biased to the unactuated position, theclinician simply pivots the closure release button assembly 62 such thatthe locking pawl 64 is moved out of engagement with the locking wall 39on the first closure link 36. When the locking pawl 64 has been movedout of engagement with the first closure link 36, the closure trigger 32may pivot back to the unactuated position. Other closure trigger lockingand release arrangements also may be employed.

Further to the above, FIGS. 13-15 illustrate the closure trigger 32 inits unactuated position which is associated with an open, or unclamped,configuration of the shaft assembly 200 in which tissue can bepositioned between the jaws of the shaft assembly 200. FIGS. 16-18illustrate the closure trigger 32 in its actuated position which isassociated with a closed, or clamped, configuration of the shaftassembly 200 in which tissue is clamped between the jaws of the shaftassembly 200. Upon comparing FIGS. 14 and 17, the reader will appreciatethat, when the closure trigger 32 is moved from its unactuated position(FIG. 14) to its actuated position (FIG. 17), the closure release button62 is pivoted between a first position (FIG. 14) and a second position(FIG. 17). The rotation of the closure release button 62 can be referredto as being an upward rotation; however, at least a portion of theclosure release button 62 is being rotated toward the circuit board 100.Referring to FIG. 4, the closure release button 62 can include an arm 61extending therefrom and a magnetic element 63, such as a permanentmagnet, for example, mounted to the arm 61. When the closure releasebutton 62 is rotated from its first position to its second position, themagnetic element 63 can move toward the circuit board 100. The circuitboard 100 can include at least one sensor configured to detect themovement of the magnetic element 63. In at least one aspect, a magneticfield sensor 65, for example, can be mounted to the bottom surface ofthe circuit board 100. The magnetic field sensor 65 can be configured todetect changes in a magnetic field surrounding the magnetic field sensor65 caused by the movement of the magnetic element 63. The magnetic fieldsensor 65 can be in signal communication with a microcontroller 1500(FIG. 19), for example, which can determine whether the closure releasebutton 62 is in its first position, which is associated with theunactuated position of the closure trigger 32 and the open configurationof the end effector, its second position, which is associated with theactuated position of the closure trigger 32 and the closed configurationof the end effector, and/or any position between the first position andthe second position.

As used throughout the present disclosure, a magnetic field sensor maybe a Hall effect sensor, search coil, fluxgate, optically pumped,nuclear precession, SQUID, Hall-effect, anisotropic magnetoresistance,giant magnetoresistance, magnetic tunnel junctions, giantmagnetoimpedance, magnetostrictive/piezoelectric composites,magnetodiode, magnetotransistor, fiber optic, magnetooptic, andmicroelectromechanical systems-based magnetic sensors, among others.

In at least one form, the handle assembly 14 and the frame 20 mayoperably support another drive system referred to herein as a firingdrive system 80 that is configured to apply firing motions tocorresponding portions of the interchangeable shaft assembly attachedthereto. The firing drive system may 80 also be referred to herein as a“second drive system”. The firing drive system 80 may employ an electricmotor 82, located in the pistol grip portion 19 of the handle assembly14. In various forms, the motor 82 may be a DC brushed driving motorhaving a maximum rotation of, approximately, 25,000 RPM, for example. Inother arrangements, the motor may include a brushless motor, a cordlessmotor, a synchronous motor, a stepper motor, or any other suitableelectric motor. The motor 82 may be powered by a power source 90 that inone form may comprise a removable power pack 92. As shown in FIG. 4, forexample, the power pack 92 may comprise a proximal housing portion 94that is configured for attachment to a distal housing portion 96. Theproximal housing portion 94 and the distal housing portion 96 areconfigured to operably support a plurality of batteries 98 therein.Batteries 98 may each comprise, for example, a Lithium Ion (“LI”) orother suitable battery. The distal housing portion 96 is configured forremovable operable attachment to a control circuit board assembly 100which is also operably coupled to the motor 82. A number of batteries 98may be connected in series may be used as the power source for thesurgical instrument 10. In addition, the power source 90 may bereplaceable and/or rechargeable.

As outlined above with respect to other various forms, the electricmotor 82 can include a rotatable shaft (not shown) that operablyinterfaces with a gear reducer assembly 84 that is mounted in meshingengagement with a with a set, or rack, of drive teeth 122 on alongitudinally-movable drive member 120. In use, a voltage polarityprovided by the power source 90 can operate the electric motor 82 in aclockwise direction wherein the voltage polarity applied to the electricmotor by the battery can be reversed in order to operate the electricmotor 82 in a counter-clockwise direction. When the electric motor 82 isrotated in one direction, the drive member 120 will be axially driven inthe distal direction “DD”. When the motor 82 is driven in the oppositerotary direction, the drive member 120 will be axially driven in aproximal direction “PD”. The handle assembly 14 can include a switchwhich can be configured to reverse the polarity applied to the electricmotor 82 by the power source 90. As with the other forms describedherein, the handle assembly 14 can also include a sensor that isconfigured to detect the position of the drive member 120 and/or thedirection in which the drive member 120 is being moved.

Actuation of the motor 82 can be controlled by a firing trigger 130 thatis pivotally supported on the handle assembly 14. The firing trigger 130may be pivoted between an unactuated position and an actuated position.The firing trigger 130 may be biased into the unactuated position by aspring 132 or other biasing arrangement such that when the clinicianreleases the firing trigger 130, it may be pivoted or otherwise returnedto the unactuated position by the spring 132 or biasing arrangement. Inat least one form, the firing trigger 130 can be positioned “outboard”of the closure trigger 32 as was discussed above. In at least one form,a firing trigger safety button 134 may be pivotally mounted to theclosure trigger 32 by pin 35. The safety button 134 may be positionedbetween the firing trigger 130 and the closure trigger 32 and have apivot arm 136 protruding therefrom. See FIG. 4. When the closure trigger32 is in the unactuated position, the safety button 134 is contained inthe handle assembly 14 where the clinician cannot readily access it andmove it between a safety position preventing actuation of the firingtrigger 130 and a firing position wherein the firing trigger 130 may befired. As the clinician depresses the closure trigger 32, the safetybutton 134 and the firing trigger 130 pivot down wherein they can thenbe manipulated by the clinician.

As discussed above, the handle assembly 14 can include a closure trigger32 and a firing trigger 130. Referring to FIGS. 14-18A, the firingtrigger 130 can be pivotably mounted to the closure trigger 32. Theclosure trigger 32 can include an arm 31 extending therefrom and thefiring trigger 130 can be pivotably mounted to the arm 31 about a pivotpin 33. When the closure trigger 32 is moved from its unactuatedposition (FIG. 14) to its actuated position (FIG. 17), the firingtrigger 130 can descend downwardly, as outlined above. After the safetybutton 134 has been moved to its firing position, referring primarily toFIG. 18A, the firing trigger 130 can be depressed to operate the motorof the surgical instrument firing system. In various instances, thehandle assembly 14 can include a tracking system, such as system 800,for example, configured to determine the position of the closure trigger32 and/or the position of the firing trigger 130. With primary referenceto FIGS. 14, 17, and 18A, the tracking system 800 can include a magneticelement, such as permanent magnet 802, for example, which is mounted toan arm 801 extending from the firing trigger 130. The tracking system800 can comprise one or more sensors, such as a first magnetic fieldsensor 803 and a second magnetic field sensor 804, for example, whichcan be configured to track the position of the magnet 802.

Upon comparing FIGS. 14 and 17, the reader will appreciate that, whenthe closure trigger 32 is moved from its unactuated position to itsactuated position, the magnet 802 can move between a first positionadjacent the first magnetic field sensor 803 and a second positionadjacent the second magnetic field sensor 804.

Upon comparing FIGS. 17 and 18A, the reader will further appreciatethat, when the firing trigger 130 is moved from an unfired position(FIG. 17) to a fired position (FIG. 18A), the magnet 802 can moverelative to the second magnetic field sensor 804. The sensors 803 and804 can track the movement of the magnet 802 and can be in signalcommunication with a microcontroller on the circuit board 100. With datafrom the first sensor 803 and/or the second sensor 804, themicrocontroller can determine the position of the magnet 802 along apredefined path and, based on that position, the microcontroller candetermine whether the closure trigger 32 is in its unactuated position,its actuated position, or a position therebetween. Similarly, with datafrom the first sensor 803 and/or the second sensor 804, themicrocontroller can determine the position of the magnet 802 along apredefined path and, based on that position, the microcontroller candetermine whether the firing trigger 130 is in its unfired position, itsfully fired position, or a position therebetween.

As indicated above, in at least one form, the longitudinally movabledrive member 120 has a rack of teeth 122 formed thereon for meshingengagement with a corresponding drive gear 86 of the gear reducerassembly 84. At least one form also includes a manually-actuatable“bailout” assembly 140 that is configured to enable the clinician tomanually retract the longitudinally movable drive member 120 should themotor 82 become disabled. The bailout assembly 140 may include a leveror bailout handle assembly 14 that is configured to be manually pivotedinto ratcheting engagement with teeth 124 also provided in the drivemember 120. Thus, the clinician can manually retract the drive member120 by using the bailout handle assembly 14 to ratchet the drive member120 in the proximal direction “PD”. U.S. Patent Application PublicationNo. US 2010/0089970, now U.S. Pat. No. 8,608,045 discloses bailoutarrangements and other components, arrangements and systems that alsomay be employed with the various instruments disclosed herein. U.S.patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,U.S. Patent Application Publication No. 2010/0089970, now U.S. Pat. No.8,608,045, is hereby incorporated by reference in its entirety.

Turning now to FIGS. 1 and 7, the interchangeable shaft assembly 200includes a surgical end effector 300 that comprises an elongated channel302 that is configured to operably support a staple cartridge 304therein. The end effector 300 may further include an anvil 306 that ispivotally supported relative to the elongated channel 302. Theinterchangeable shaft assembly 200 may further include an articulationjoint 270 and an articulation lock 350 (FIG. 8) which can be configuredto releasably hold the end effector 300 in a desired position relativeto a shaft axis SA-SA. Details regarding the construction and operationof the end effector 300, the articulation joint 270 and the articulationlock 350 are set forth in U.S. patent application Ser. No. 13/803,086,filed Mar. 14, 2013, entitled ARTICULATABLE SURGICAL INSTRUMENTCOMPRISING AN ARTICULATION LOCK, now U.S. Patent Application PublicationNo. 2014/0263541. The entire disclosure of U.S. patent application Ser.No. 13/803,086, filed Mar. 14, 2013, entitled ARTICULATABLE SURGICALINSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. Patent ApplicationPublication No. 2014/0263541, is hereby incorporated by referenceherein. As shown in FIGS. 7 and 8, the interchangeable shaft assembly200 can further include a proximal housing or nozzle 201 comprised ofnozzle portions 202 and 203. The interchangeable shaft assembly 200 canfurther include a closure tube 260 which can be utilized to close and/oropen the anvil 306 of the end effector 300. Primarily referring now toFIGS. 8 and 9, the shaft assembly 200 can include a spine 210 which canbe configured to fixably support a shaft frame portion 212 of thearticulation lock 350. See FIG. 8. The spine 210 can be configured to,one, slidably support a firing member 220 therein and, two, slidablysupport the closure tube 260 which extends around the spine 210. Thespine 210 can also be configured to slidably support a proximalarticulation driver 230. The articulation driver 230 has a distal end231 that is configured to operably engage the articulation lock 350. Thearticulation lock 350 interfaces with an articulation frame 352 that isadapted to operably engage a drive pin (not shown) on the end effectorframe (not shown). As indicated above, further details regarding theoperation of the articulation lock 350 and the articulation frame may befound in U.S. patent application Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541. In various circumstances, thespine 210 can comprise a proximal end 211 which is rotatably supportedin a chassis 240. In one arrangement, for example, the proximal end 211of the spine 210 has a thread 214 formed thereon for threaded attachmentto a spine bearing 216 configured to be supported within the chassis240. See FIG. 7. Such an arrangement facilitates rotatable attachment ofthe spine 210 to the chassis 240 such that the spine 210 may beselectively rotated about a shaft axis SA-SA relative to the chassis240.

Referring primarily to FIG. 7, the interchangeable shaft assembly 200includes a closure shuttle 250 that is slidably supported within thechassis 240 such that it may be axially moved relative thereto. As shownin FIGS. 3 and 7, the closure shuttle 250 includes a pair ofproximally-protruding hooks 252 that are configured for attachment tothe attachment pin 37 that is attached to the second closure link 38 aswill be discussed in further detail below. A proximal end 261 of theclosure tube 260 is coupled to the closure shuttle 250 for relativerotation thereto. For example, a U shaped connector 263 is inserted intoan annular slot 262 in the proximal end 261 of the closure tube 260 andis retained within vertical slots 253 in the closure shuttle 250. SeeFIG. 7. Such an arrangement serves to attach the closure tube 260 to theclosure shuttle 250 for axial travel therewith while enabling theclosure tube 260 to rotate relative to the closure shuttle 250 about theshaft axis SA-SA. A closure spring 268 is journaled on the closure tube260 and serves to bias the closure tube 260 in the proximal direction“PD” which can serve to pivot the closure trigger into the unactuatedposition when the shaft assembly is operably coupled to the handleassembly 14.

In at least one form, the interchangeable shaft assembly 200 may furtherinclude an articulation joint 270. Other interchangeable shaftassemblies, however, may not be capable of articulation. As shown inFIG. 7, for example, the articulation joint 270 includes a double pivotclosure sleeve assembly 271. According to various forms, the doublepivot closure sleeve assembly 271 includes an end effector closuresleeve assembly 272 having upper and lower distally projecting tangs273, 274. An end effector closure sleeve assembly 272 includes ahorseshoe aperture 275 and a tab 276 for engaging an opening tab on theanvil 306 in the various manners described in U.S. patent applicationSer. No. 13/803,086, filed Mar. 14, 2013, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. PatentApplication Publication No. 2014/0263541, which has been incorporated byreference herein. As described in further detail therein, the horseshoeaperture 275 and tab 276 engage a tab on the anvil when the anvil 306 isopened. An upper double pivot link 277 includes upwardly projectingdistal and proximal pivot pins that engage respectively an upper distalpin hole in the upper proximally projecting tang 273 and an upperproximal pin hole in an upper distally projecting tang 264 on theclosure tube 260. A lower double pivot link 278 includes upwardlyprojecting distal and proximal pivot pins that engage respectively alower distal pin hole in the lower proximally projecting tang 274 and alower proximal pin hole in the lower distally projecting tang 265. Seealso FIG. 8.

In use, the closure tube 260 is translated distally (direction “DD”) toclose the anvil 306, for example, in response to the actuation of theclosure trigger 32. The anvil 306 is closed by distally translating theclosure tube 260 and thus the shaft closure sleeve assembly 272, causingit to strike a proximal surface on the anvil 360 in the manner describedin the aforementioned reference U.S. patent application Ser. No.13/803,086, now U.S. Patent Application Publication No. 2014/0263541. Aswas also described in detail in that reference, the anvil 306 is openedby proximally translating the closure tube 260 and the shaft closuresleeve assembly 272, causing tab 276 and the horseshoe aperture 275 tocontact and push against the anvil tab to lift the anvil 306. In theanvil-open position, the shaft closure tube 260 is moved to its proximalposition.

As indicated above, the surgical instrument 10 may further include anarticulation lock 350 of the types and construction described in furtherdetail in U.S. patent application Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541, which can be configured andoperated to selectively lock the end effector 300 in position. Sucharrangement enables the end effector 300 to be rotated, or articulated,relative to the shaft closure tube 260 when the articulation lock 350 isin its unlocked state. In such an unlocked state, the end effector 300can be positioned and pushed against soft tissue and/or bone, forexample, surrounding the surgical site within the patient in order tocause the end effector 300 to articulate relative to the closure tube260. The end effector 300 also may be articulated relative to theclosure tube 260 by an articulation driver 230.

As was also indicated above, the interchangeable shaft assembly 200further includes a firing member 220 that is supported for axial travelwithin the shaft spine 210. The firing member 220 includes anintermediate firing shaft portion 222 that is configured for attachmentto a distal cutting portion or knife bar 280. The firing member 220 alsomay be referred to herein as a “second shaft” and/or a “second shaftassembly”. As shown in FIGS. 8 and 9, the intermediate firing shaftportion 222 may include a longitudinal slot 223 in the distal endthereof which can be configured to receive a tab 284 on the proximal end282 of the distal knife bar 280. The longitudinal slot 223 and theproximal end 282 can be sized and configured to permit relative movementtherebetween and can comprise a slip joint 286. The slip joint 286 canpermit the intermediate firing shaft portion 222 of the firing drive 220to be moved to articulate the end effector 300 without moving, or atleast substantially moving, the knife bar 280. Once the end effector 300has been suitably oriented, the intermediate firing shaft portion 222can be advanced distally until a proximal sidewall of the longitudinalslot 223 comes into contact with the tab 284 in order to advance theknife bar 280 and fire the staple cartridge positioned within thechannel 302 As can be further seen in FIGS. 8 and 9, the shaft spine 210has an elongate opening or window 213 therein to facilitate assembly andinsertion of the intermediate firing shaft portion 222 into the shaftframe 210. Once the intermediate firing shaft portion 222 has beeninserted therein, a top frame segment 215 may be engaged with the shaftframe 212 to enclose the intermediate firing shaft portion 222 and knifebar 280 therein. Further description of the operation of the firingmember 220 may be found in U.S. patent application Ser. No. 13/803,086,now U.S. Patent Application Publication No. 2014/0263541.

Further to the above, the shaft assembly 200 can include a clutchassembly 400 which can be configured to selectively and releasablycouple the articulation driver 230 to the firing member 220. In oneform, the clutch assembly 400 includes a lock collar, or sleeve 402,positioned around the firing member 220 wherein the lock sleeve 402 canbe rotated between an engaged position in which the lock sleeve 402couples the articulation driver 360 to the firing member 220 and adisengaged position in which the articulation driver 360 is not operablycoupled to the firing member 200. When lock sleeve 402 is in its engagedposition, distal movement of the firing member 220 can move thearticulation driver 360 distally and, correspondingly, proximal movementof the firing member 220 can move the articulation driver 230proximally. When lock sleeve 402 is in its disengaged position, movementof the firing member 220 is not transmitted to the articulation driver230 and, as a result, the firing member 220 can move independently ofthe articulation driver 230. In various circumstances, the articulationdriver 230 can be held in position by the articulation lock 350 when thearticulation driver 230 is not being moved in the proximal or distaldirections by the firing member 220.

Referring primarily to FIG. 9, the lock sleeve 402 can comprise acylindrical, or an at least substantially cylindrical, body including alongitudinal aperture 403 defined therein configured to receive thefiring member 220. The lock sleeve 402 can comprisediametrically-opposed, inwardly-facing lock protrusions 404 and anoutwardly-facing lock member 406. The lock protrusions 404 can beconfigured to be selectively engaged with the firing member 220. Moreparticularly, when the lock sleeve 402 is in its engaged position, thelock protrusions 404 are positioned within a drive notch 224 defined inthe firing member 220 such that a distal pushing force and/or a proximalpulling force can be transmitted from the firing member 220 to the locksleeve 402. When the lock sleeve 402 is in its engaged position, thesecond lock member 406 is received within a drive notch 232 defined inthe articulation driver 230 such that the distal pushing force and/orthe proximal pulling force applied to the lock sleeve 402 can betransmitted to the articulation driver 230. In effect, the firing member220, the lock sleeve 402, and the articulation driver 230 will movetogether when the lock sleeve 402 is in its engaged position. On theother hand, when the lock sleeve 402 is in its disengaged position, thelock protrusions 404 may not be positioned within the drive notch 224 ofthe firing member 220 and, as a result, a distal pushing force and/or aproximal pulling force may not be transmitted from the firing member 220to the lock sleeve 402. Correspondingly, the distal pushing force and/orthe proximal pulling force may not be transmitted to the articulationdriver 230. In such circumstances, the firing member 220 can be slidproximally and/or distally relative to the lock sleeve 402 and theproximal articulation driver 230.

As shown in FIGS. 8-12, the shaft assembly 200 further includes a switchdrum 500 that is rotatably received on the closure tube 260. The switchdrum 500 comprises a hollow shaft segment 502 that has a shaft boss 504formed thereon for receive an outwardly protruding actuation pin 410therein. In various circumstances, the actuation pin 410 extends througha slot 267 into a longitudinal slot 408 provided in the lock sleeve 402to facilitate axial movement of the lock sleeve 402 when it is engagedwith the articulation driver 230. A rotary torsion spring 420 isconfigured to engage the boss 504 on the switch drum 500 and a portionof the nozzle housing 203 as shown in FIG. 10 to apply a biasing forceto the switch drum 500. The switch drum 500 can further comprise atleast partially circumferential openings 506 defined therein which,referring to FIGS. 5 and 6, can be configured to receive circumferentialmounts 204, 205 extending from the nozzle halves 202, 203 and permitrelative rotation, but not translation, between the switch drum 500 andthe proximal nozzle 201. As shown in those Figures, the mounts 204 and205 also extend through openings 266 in the closure tube 260 to beseated in recesses 211 in the shaft spine 210. However, rotation of thenozzle 201 to a point where the mounts 204, 205 reach the end of theirrespective slots 506 in the switch drum 500 will result in rotation ofthe switch drum 500 about the shaft axis SA-SA. Rotation of the switchdrum 500 will ultimately result in the rotation of eth actuation pin 410and the lock sleeve 402 between its engaged and disengaged positions.Thus, in essence, the nozzle 201 may be employed to operably engage anddisengage the articulation drive system with the firing drive system inthe various manners described in further detail in U.S. patentapplication Ser. No. 13/803,086, now U.S. Patent Application PublicationNo. 2014/0263541.

As also illustrated in FIGS. 8-12, the shaft assembly 200 can comprise aslip ring assembly 600 which can be configured to conduct electricalpower to and/or from the end effector 300 and/or communicate signals toand/or from the end effector 300, for example. The slip ring assembly600 can comprise a proximal connector flange 604 mounted to a chassisflange 242 extending from the chassis 240 and a distal connector flange601 positioned within a slot defined in the shaft housings 202, 203. Theproximal connector flange 604 can comprise a first face and the distalconnector flange 601 can comprise a second face which is positionedadjacent to and movable relative to the first face. The distal connectorflange 601 can rotate relative to the proximal connector flange 604about the shaft axis SA-SA. The proximal connector flange 604 cancomprise a plurality of concentric, or at least substantiallyconcentric, conductors 602 defined in the first face thereof. Aconnector 607 can be mounted on the proximal side of the connectorflange 601 and may have a plurality of contacts (not shown) wherein eachcontact corresponds to and is in electrical contact with one of theconductors 602. Such an arrangement permits relative rotation betweenthe proximal connector flange 604 and the distal connector flange 601while maintaining electrical contact therebetween. The proximalconnector flange 604 can include an electrical connector 606 which canplace the conductors 602 in signal communication with a shaft circuitboard 610 mounted to the shaft chassis 240, for example. In at least oneinstance, a wiring harness comprising a plurality of conductors canextend between the electrical connector 606 and the shaft circuit board610. The electrical connector 606 may extend proximally through aconnector opening 243 defined in the chassis mounting flange 242. SeeFIG. 7. U.S. patent application Ser. No. 13/800,067, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, nowU.S. Patent Application Publication No. 2014/0263552, is incorporated byreference in its entirety. U.S. patent application Ser. No. 13/800,025,entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar.13, 2013, now U.S. Patent Application Publication No. 2014/0263551, isincorporated by reference in its entirety. Further details regardingslip ring assembly 600 may be found in U.S. patent application Ser. No.13/803,086, now U.S. Patent Application Publication No. 2014/0263541.

As discussed above, the shaft assembly 200 can include a proximalportion which is fixably mounted to the handle assembly 14 and a distalportion which is rotatable about a longitudinal axis. The rotatabledistal shaft portion can be rotated relative to the proximal portionabout the slip ring assembly 600, as discussed above. The distalconnector flange 601 of the slip ring assembly 600 can be positionedwithin the rotatable distal shaft portion. Moreover, further to theabove, the switch drum 500 can also be positioned within the rotatabledistal shaft portion. When the rotatable distal shaft portion isrotated, the distal connector flange 601 and the switch drum 500 can berotated synchronously with one another. In addition, the switch drum 500can be rotated between a first position and a second position relativeto the distal connector flange 601. When the switch drum 500 is in itsfirst position, the articulation drive system may be operably disengagedfrom the firing drive system and, thus, the operation of the firingdrive system may not articulate the end effector 300 of the shaftassembly 200. When the switch drum 500 is in its second position, thearticulation drive system may be operably engaged with the firing drivesystem and, thus, the operation of the firing drive system mayarticulate the end effector 300 of the shaft assembly 200. When theswitch drum 500 is moved between its first position and its secondposition, the switch drum 500 is moved relative to distal connectorflange 601. In various instances, the shaft assembly 200 can comprise atleast one sensor configured to detect the position of the switch drum500. Turning now to FIGS. 11 and 12, the distal connector flange 601 cancomprise a magnetic field sensor 605, for example, and the switch drum500 can comprise a magnetic element, such as permanent magnet 505, forexample. The magnetic field sensor 605 can be configured to detect theposition of the permanent magnet 505. When the switch drum 500 isrotated between its first position and its second position, thepermanent magnet 505 can move relative to the magnetic field sensor 605.In various instances, magnetic field sensor 605 can detect changes in amagnetic field created when the permanent magnet 505 is moved. Themagnetic field sensor 605 can be in signal communication with the shaftcircuit board 610 and/or the handle circuit board 100, for example.Based on the signal from the magnetic field sensor 605, amicrocontroller on the shaft circuit board 610 and/or the handle circuitboard 100 can determine whether the articulation drive system is engagedwith or disengaged from the firing drive system.

Referring again to FIGS. 3 and 7, the chassis 240 includes at least one,and preferably two, tapered attachment portions 244 formed thereon thatare adapted to be received within corresponding dovetail slots 702formed within a distal attachment flange portion 700 of the frame 20.Each dovetail slot 702 may be tapered or, stated another way, besomewhat V-shaped to seatingly receive the attachment portions 244therein. As can be further seen in FIGS. 3 and 7, a shaft attachment lug226 is formed on the proximal end of the intermediate firing shaft 222.As will be discussed in further detail below, when the interchangeableshaft assembly 200 is coupled to the handle assembly 14, the shaftattachment lug 226 is received in a firing shaft attachment cradle 126formed in the distal end 125 of the longitudinal drive member 120 asshown in FIGS. 3 and 6, for example.

Various shaft assemblies employ a latch system 710 for removablycoupling the shaft assembly 200 to the housing 12 and more specificallyto the frame 20. As shown in FIG. 7, for example, in at least one form,the latch system 710 includes a lock member or lock yoke 712 that ismovably coupled to the chassis 240. In the illustrated example, forexample, the lock yoke 712 has a U-shape with two spaced downwardlyextending legs 714. The legs 714 each have a pivot lug 716 formedthereon that are adapted to be received in corresponding holes 245formed in the chassis 240. Such arrangement facilitates pivotalattachment of the lock yoke 712 to the chassis 240. The lock yoke 712may include two proximally protruding lock lugs 714 that are configuredfor releasable engagement with corresponding lock detents or grooves 704in the distal attachment flange 700 of the frame 20. See FIG. 3. Invarious forms, the lock yoke 712 is biased in the proximal direction byspring or biasing member (not shown). Actuation of the lock yoke 712 maybe accomplished by a latch button 722 that is slidably mounted on alatch actuator assembly 720 that is mounted to the chassis 240. Thelatch button 722 may be biased in a proximal direction relative to thelock yoke 712. As will be discussed in further detail below, the lockyoke 712 may be moved to an unlocked position by biasing the latchbutton the in distal direction which also causes the lock yoke 712 topivot out of retaining engagement with the distal attachment flange 700of the frame 20. When the lock yoke 712 is in “retaining engagement”with the distal attachment flange 700 of the frame 20, the lock lugs 716are retainingly seated within the corresponding lock detents or grooves704 in the distal attachment flange 700.

When employing an interchangeable shaft assembly that includes an endeffector of the type described herein that is adapted to cut and fastentissue, as well as other types of end effectors, it may be desirable toprevent inadvertent detachment of the interchangeable shaft assemblyfrom the housing during actuation of the end effector. For example, inuse the clinician may actuate the closure trigger 32 to grasp andmanipulate the target tissue into a desired position. Once the targettissue is positioned within the end effector 300 in a desiredorientation, the clinician may then fully actuate the closure trigger 32to close the anvil 306 and clamp the target tissue in position forcutting and stapling. In that instance, the first drive system 30 hasbeen fully actuated. After the target tissue has been clamped in the endeffector 300, it may be desirable to prevent the inadvertent detachmentof the shaft assembly 200 from the housing 12. One form of the latchsystem 710 is configured to prevent such inadvertent detachment.

As can be most particularly seen in FIG. 7, the lock yoke 712 includesat least one and preferably two lock hooks 718 that are adapted tocontact corresponding lock lug portions 256 that are formed on theclosure shuttle 250. Referring to FIGS. 13-15, when the closure shuttle250 is in an unactuated position (i.e., the first drive system 30 isunactuated and the anvil 306 is open), the lock yoke 712 may be pivotedin a distal direction to unlock the interchangeable shaft assembly 200from the housing 12. When in that position, the lock hooks 718 do notcontact the lock lug portions 256 on the closure shuttle 250. However,when the closure shuttle 250 is moved to an actuated position (i.e., thefirst drive system 30 is actuated and the anvil 306 is in the closedposition), the lock yoke 712 is prevented from being pivoted to anunlocked position. See FIGS. 16-18. Stated another way, if the clinicianwere to attempt to pivot the lock yoke 712 to an unlocked position or,for example, the lock yoke 712 was in advertently bumped or contacted ina manner that might otherwise cause it to pivot distally, the lock hooks718 on the lock yoke 712 will contact the lock lugs 256 on the closureshuttle 250 and prevent movement of the lock yoke 712 to an unlockedposition.

Attachment of the interchangeable shaft assembly 200 to the handleassembly 14 will now be described with reference to FIG. 3. To commencethe coupling process, the clinician may position the chassis 240 of theinterchangeable shaft assembly 200 above or adjacent to the distalattachment flange 700 of the frame 20 such that the tapered attachmentportions 244 formed on the chassis 240 are aligned with the dovetailslots 702 in the frame 20. The clinician may then move the shaftassembly 200 along an installation axis IA that is perpendicular to theshaft axis SA-SA to seat the attachment portions 244 in “operableengagement” with the corresponding dovetail receiving slots 702. Indoing so, the shaft attachment lug 226 on the intermediate firing shaft222 will also be seated in the cradle 126 in the longitudinally movabledrive member 120 and the portions of pin 37 on the second closure link38 will be seated in the corresponding hooks 252 in the closure yoke250. As used herein, the term “operable engagement” in the context oftwo components means that the two components are sufficiently engagedwith each other so that upon application of an actuation motion thereto,the components may carry out their intended action, function and/orprocedure.

As discussed above, at least five systems of the interchangeable shaftassembly 200 can be operably coupled with at least five correspondingsystems of the handle assembly 14. A first system can comprise a framesystem which couples and/or aligns the frame or spine of the shaftassembly 200 with the frame 20 of the handle assembly 14. Another systemcan comprise a closure drive system 30 which can operably connect theclosure trigger 32 of the handle assembly 14 and the closure tube 260and the anvil 306 of the shaft assembly 200. As outlined above, theclosure tube attachment yoke 250 of the shaft assembly 200 can beengaged with the pin 37 on the second closure link 38. Another systemcan comprise the firing drive system 80 which can operably connect thefiring trigger 130 of the handle assembly 14 with the intermediatefiring shaft 222 of the shaft assembly 200.

As outlined above, the shaft attachment lug 226 can be operablyconnected with the cradle 126 of the longitudinal drive member 120.Another system can comprise an electrical system which can signal to acontroller in the handle assembly 14, such as microcontroller, forexample, that a shaft assembly, such as shaft assembly 200, for example,has been operably engaged with the handle assembly 14 and/or, two,conduct power and/or communication signals between the shaft assembly200 and the handle assembly 14. For instance, the shaft assembly 200 caninclude an electrical connector 1410 that is operably mounted to theshaft circuit board 610. The electrical connector 1410 is configured formating engagement with a corresponding electrical connector 1400 on thehandle control board 100. Further details regaining the circuitry andcontrol systems may be found in U.S. patent application Ser. No.13/803,086, the entire disclosure of which was previously incorporatedby reference herein. The fifth system may consist of the latching systemfor releasably locking the shaft assembly 200 to the handle assembly 14.

Referring again to FIGS. 2 and 3, the handle assembly 14 can include anelectrical connector 1400 comprising a plurality of electrical contacts.Turning now to FIG. 19, the electrical connector 1400 can comprise afirst contact 1401 a, a second contact 1401 b, a third contact 1401 c, afourth contact 1401 d, a fifth contact 1401 e, and a sixth contact 1401f, for example. While the illustrated example utilizes six contacts,other examples are envisioned which may utilize more than six contactsor less than six contacts.

As illustrated in FIG. 19, the first contact 1401 a can be in electricalcommunication with a transistor 1408, contacts 1401 b-1401 e can be inelectrical communication with a microcontroller 1500, and the sixthcontact 1401 f can be in electrical communication with a ground. Incertain circumstances, one or more of the electrical contacts 1401b-1401 e may be in electrical communication with one or more outputchannels of the microcontroller 1500 and can be energized, or have avoltage potential applied thereto, when the handle 1042 is in a poweredstate. In some circumstances, one or more of the electrical contacts1401 b-1401 e may be in electrical communication with one or more inputchannels of the microcontroller 1500 and, when the handle assembly 14 isin a powered state, the microcontroller 1500 can be configured to detectwhen a voltage potential is applied to such electrical contacts. When ashaft assembly, such as shaft assembly 200, for example, is assembled tothe handle assembly 14, the electrical contacts 1401 a-1401 f may notcommunicate with each other. When a shaft assembly is not assembled tothe handle assembly 14, however, the electrical contacts 1401 a-1401 fof the electrical connector 1400 may be exposed and, in somecircumstances, one or more of the contacts 1401 a-1401 f may beaccidentally placed in electrical communication with each other. Suchcircumstances can arise when one or more of the contacts 1401 a-1401 fcome into contact with an electrically conductive material, for example.When this occurs, the microcontroller 1500 can receive an erroneousinput and/or the shaft assembly 200 can receive an erroneous output, forexample. To address this issue, in various circumstances, the handleassembly 14 may be unpowered when a shaft assembly, such as shaftassembly 200, for example, is not attached to the handle assembly 14.

In other circumstances, the handle 1042 can be powered when a shaftassembly, such as shaft assembly 200, for example, is not attachedthereto. In such circumstances, the microcontroller 1500 can beconfigured to ignore inputs, or voltage potentials, applied to thecontacts in electrical communication with the microcontroller 1500,i.e., contacts 1401 b-1401 e, for example, until a shaft assembly isattached to the handle assembly 14. Even though the microcontroller 1500may be supplied with power to operate other functionalities of thehandle assembly 14 in such circumstances, the handle assembly 14 may bein a powered-down state. In a way, the electrical connector 1400 may bein a powered-down state as voltage potentials applied to the electricalcontacts 1401 b-1401 e may not affect the operation of the handleassembly 14. The reader will appreciate that, even though contacts 1401b-1401 e may be in a powered-down state, the electrical contacts 1401 aand 1401 f, which are not in electrical communication with themicrocontroller 1500, may or may not be in a powered-down state. Forinstance, sixth contact 1401 f may remain in electrical communicationwith a ground regardless of whether the handle assembly 14 is in apowered-up or a powered-down state.

Furthermore, the transistor 1408, and/or any other suitable arrangementof transistors, such as transistor 1410, for example, and/or switchesmay be configured to control the supply of power from a power source1404, such as a battery 90 within the handle assembly 14, for example,to the first electrical contact 1401 a regardless of whether the handleassembly 14 is in a powered-up or a powered-down state. In variouscircumstances, the shaft assembly 200, for example, can be configured tochange the state of the transistor 1408 when the shaft assembly 200 isengaged with the handle assembly 14. In certain circumstances, furtherto the below, a magnetic field sensor 1402 can be configured to switchthe state of transistor 1410 which, as a result, can switch the state oftransistor 1408 and ultimately supply power from power source 1404 tofirst contact 1401 a. In this way, both the power circuits and thesignal circuits to the connector 1400 can be powered down when a shaftassembly is not installed to the handle assembly 14 and powered up whena shaft assembly is installed to the handle assembly 14.

In various circumstances, referring again to FIG. 19, the handleassembly 14 can include the magnetic field sensor 1402, for example,which can be configured to detect a detectable element, such as amagnetic element 1407 (FIG. 3), for example, on a shaft assembly, suchas shaft assembly 200, for example, when the shaft assembly is coupledto the handle assembly 14. The magnetic field sensor 1402 can be poweredby a power source 1406, such as a battery, for example, which can, ineffect, amplify the detection signal of the magnetic field sensor 1402and communicate with an input channel of the microcontroller 1500 viathe circuit illustrated in FIG. 19. Once the microcontroller 1500 has areceived an input indicating that a shaft assembly has been at leastpartially coupled to the handle assembly 14, and that, as a result, theelectrical contacts 1401 a-1401 f are no longer exposed, themicrocontroller 1500 can enter into its normal, or powered-up, operatingstate. In such an operating state, the microcontroller 1500 willevaluate the signals transmitted to one or more of the contacts 1401b-1401 e from the shaft assembly and/or transmit signals to the shaftassembly through one or more of the contacts 1401 b-1401 e in normal usethereof. In various circumstances, the shaft assembly 200 may have to befully seated before the magnetic field sensor 1402 can detect themagnetic element 1407. While a magnetic field sensor 1402 can beutilized to detect the presence of the shaft assembly 200, any suitablesystem of sensors and/or switches can be utilized to detect whether ashaft assembly has been assembled to the handle assembly 14, forexample. In this way, further to the above, both the power circuits andthe signal circuits to the connector 1400 can be powered down when ashaft assembly is not installed to the handle assembly 14 and powered upwhen a shaft assembly is installed to the handle assembly 14.

In various examples, as may be used throughout the present disclosure,any suitable magnetic field sensor may be employed to detect whether ashaft assembly has been assembled to the handle assembly 14, forexample. For example, the technologies used for magnetic field sensinginclude Hall effect sensor, search coil, fluxgate, optically pumped,nuclear precession, SQUID, Hall-effect, anisotropic magnetoresistance,giant magnetoresistance, magnetic tunnel junctions, giantmagnetoimpedance, magnetostrictive/piezoelectric composites,magnetodiode, magnetotransistor, fiber optic, magnetooptic, andmicroelectromechanical systems-based magnetic sensors, among others.

Referring to FIG. 19, the microcontroller 1500 may generally comprise amicroprocessor (“processor”) and one or more memory units operationallycoupled to the processor. By executing instruction code stored in thememory, the processor may control various components of the surgicalinstrument, such as the motor, various drive systems, and/or a userdisplay, for example. The microcontroller 1500 may be implemented usingintegrated and/or discrete hardware elements, software elements, and/ora combination of both. Examples of integrated hardware elements mayinclude processors, microprocessors, microcontrollers, integratedcircuits, application specific integrated circuits (ASIC), programmablelogic devices (PLD), digital signal processors (DSP), field programmablegate arrays (FPGA), logic gates, registers, semiconductor devices,chips, microchips, chip sets, microcontrollers, system-on-chip (SoC),and/or system-in-package (SIP). Examples of discrete hardware elementsmay include circuits and/or circuit elements such as logic gates, fieldeffect transistors, bipolar transistors, resistors, capacitors,inductors, and/or relays. In certain instances, the microcontroller 1500may include a hybrid circuit comprising discrete and integrated circuitelements or components on one or more substrates, for example.

Referring to FIG. 19, the microcontroller 1500 may be an LM 4F230H5QR,available from Texas Instruments, for example. In certain instances, theTexas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available. Other microcontrollersmay be readily substituted for use with the present disclosure.Accordingly, the present disclosure should not be limited in thiscontext.

As discussed above, the handle assembly 14 and/or the shaft assembly 200can include systems and configurations configured to prevent, or atleast reduce the possibility of, the contacts of the handle electricalconnector 1400 and/or the contacts of the shaft electrical connector1410 from becoming shorted out when the shaft assembly 200 is notassembled, or completely assembled, to the handle assembly 14. Referringto FIG. 3, the handle electrical connector 1400 can be at leastpartially recessed within a cavity 1409 defined in the handle frame 20.The six contacts 1401 a-1401 f of the electrical connector 1400 can becompletely recessed within the cavity 1409. Such arrangements can reducethe possibility of an object accidentally contacting one or more of thecontacts 1401 a-1401 f. Similarly, the shaft electrical connector 1410can be positioned within a recess defined in the shaft chassis 240 whichcan reduce the possibility of an object accidentally contacting one ormore of the contacts 1411 a-1411 f of the shaft electrical connector1410. With regard to the particular example depicted in FIG. 3, theshaft contacts 1411 a-1411 f can comprise male contacts. In at least oneexample, each shaft contact 1411 a-1411 f can comprise a flexibleprojection extending therefrom which can be configured to engage acorresponding handle contact 1401 a-1401 f, for example. The handlecontacts 1401 a-1401 f can comprise female contacts. In at least oneexample, each handle contact 1401 a-1401 f can comprise a flat surface,for example, against which the male shaft contacts 1401 a-1401 f canwipe, or slide, against and maintain an electrically conductiveinterface therebetween. In various instances, the direction in which theshaft assembly 200 is assembled to the handle assembly 14 can beparallel to, or at least substantially parallel to, the handle contacts1401 a-1401 f such that the shaft contacts 1411 a-1411 f slide againstthe handle contacts 1401 a-1401 f when the shaft assembly 200 isassembled to the handle assembly 14. In various alternative examples,the handle contacts 1401 a-1401 f can comprise male contacts and theshaft contacts 1411 a-1411 f can comprise female contacts. In certainalternative examples, the handle contacts 1401 a-1401 f and the shaftcontacts 1411 a-1411 f can comprise any suitable arrangement ofcontacts.

In various instances, the handle assembly 14 can comprise a connectorguard configured to at least partially cover the handle electricalconnector 1400 and/or a connector guard configured to at least partiallycover the shaft electrical connector 1410. A connector guard canprevent, or at least reduce the possibility of, an object accidentallytouching the contacts of an electrical connector when the shaft assemblyis not assembled to, or only partially assembled to, the handle. Aconnector guard can be movable. For instance, the connector guard can bemoved between a guarded position in which it at least partially guards aconnector and an unguarded position in which it does not guard, or atleast guards less of, the connector. In at least one example, aconnector guard can be displaced as the shaft assembly is beingassembled to the handle. For instance, if the handle comprises a handleconnector guard, the shaft assembly can contact and displace the handleconnector guard as the shaft assembly is being assembled to the handle.Similarly, if the shaft assembly comprises a shaft connector guard, thehandle can contact and displace the shaft connector guard as the shaftassembly is being assembled to the handle. In various instances, aconnector guard can comprise a door, for example. In at least oneinstance, the door can comprise a beveled surface which, when contactedby the handle or shaft, can facilitate the displacement of the door in acertain direction. In various instances, the connector guard can betranslated and/or rotated, for example. In certain instances, aconnector guard can comprise at least one film which covers the contactsof an electrical connector. When the shaft assembly is assembled to thehandle, the film can become ruptured. In at least one instance, the malecontacts of a connector can penetrate the film before engaging thecorresponding contacts positioned underneath the film.

As described above, the surgical instrument can include a system whichcan selectively power-up, or activate, the contacts of an electricalconnector, such as the electrical connector 1400, for example. Invarious instances, the contacts can be transitioned between anunactivated condition and an activated condition. In certain instances,the contacts can be transitioned between a monitored condition, adeactivated condition, and an activated condition. For instance, themicrocontroller 1500, for example, can monitor the contacts 1401 a-1401f when a shaft assembly has not been assembled to the handle assembly 14to determine whether one or more of the contacts 1401 a-1401 f may havebeen shorted. The microcontroller 1500 can be configured to apply a lowvoltage potential to each of the contacts 1401 a-1401 f and assesswhether only a minimal resistance is present at each of the contacts.Such an operating state can comprise the monitored condition. In theevent that the resistance detected at a contact is high, or above athreshold resistance, the microcontroller 1500 can deactivate thatcontact, more than one contact, or, alternatively, all of the contacts.Such an operating state can comprise the deactivated condition. If ashaft assembly is assembled to the handle assembly 14 and it is detectedby the microcontroller 1500, as discussed above, the microcontroller1500 can increase the voltage potential to the contacts 1401 a-1401 f.Such an operating state can comprise the activated condition.

The various shaft assemblies disclosed herein may employ sensors andvarious other components that require electrical communication with thecontroller in the housing. These shaft assemblies generally areconfigured to be able to rotate relative to the housing necessitating aconnection that facilitates such electrical communication between two ormore components that may rotate relative to each other. When employingend effectors of the types disclosed herein, the connector arrangementsmust be relatively robust in nature while also being somewhat compact tofit into the shaft assembly connector portion.

Referring to FIG. 20, a non-limiting form of the end effector 300 isillustrated. As described above, the end effector 300 may include theanvil 306 and the staple cartridge 304. In this non-limiting example,the anvil 306 is coupled to an elongate channel 198. For example,apertures 199 can be defined in the elongate channel 198 which canreceive pins 152 extending from the anvil 306 and allow the anvil 306 topivot from an open position to a closed position relative to theelongate channel 198 and staple cartridge 304. In addition, FIG. 20shows a firing bar 172, configured to longitudinally translate into theend effector 300. The firing bar 172 may be constructed from one solidsection, or in various examples, may include a laminate materialcomprising, for example, a stack of steel plates. A distally projectingend of the firing bar 172 can be attached to an E-beam 178 that can,among other things, assist in spacing the anvil 306 from a staplecartridge 304 positioned in the elongate channel 198 when the anvil 306is in a closed position. The E-beam 178 can also include a sharpenedcutting edge 182 which can be used to sever tissue as the E-beam 178 isadvanced distally by the firing bar 172. In operation, the E-beam 178can also actuate, or fire, the staple cartridge 304. The staplecartridge 304 can include a molded cartridge body 194 that holds aplurality of staples 191 resting upon staple drivers 192 withinrespective upwardly open staple cavities 195. A wedge sled 190 is drivendistally by the E-beam 178, sliding upon a cartridge tray 196 that holdstogether the various components of the replaceable staple cartridge 304.The wedge sled 190 upwardly cams the staple drivers 192 to force out thestaples 191 into deforming contact with the anvil 306 while a cuttingsurface 182 of the E-beam 178 severs clamped tissue.

Further to the above, the E-beam 178 can include upper pins 180 whichengage the anvil 306 during firing. The E-beam 178 can further includemiddle pins 184 and a bottom foot 186 which can engage various portionsof the cartridge body 194, cartridge tray 196 and elongate channel 198.When a staple cartridge 304 is positioned within the elongate channel198, a slot 193 defined in the cartridge body 194 can be aligned with aslot 197 defined in the cartridge tray 196 and a slot 189 defined in theelongate channel 198. In use, the E-beam 178 can slide through thealigned slots 193, 197, and 189 wherein, as indicated in FIG. 20, thebottom foot 186 of the E-beam 178 can engage a groove running along thebottom surface of channel 198 along the length of slot 189, the middlepins 184 can engage the top surfaces of cartridge tray 196 along thelength of longitudinal slot 197, and the upper pins 180 can engage theanvil 306. In such circumstances, the E-beam 178 can space, or limit therelative movement between, the anvil 306 and the staple cartridge 304 asthe firing bar 172 is moved distally to fire the staples from the staplecartridge 304 and/or incise the tissue captured between the anvil 306and the staple cartridge 304. Thereafter, the firing bar 172 and theE-beam 178 can be retracted proximally allowing the anvil 306 to beopened to release the two stapled and severed tissue portions (notshown).

Having described a surgical instrument 10 (FIGS. 1-4) in general terms,the description now turns to a detailed description of variouselectrical/electronic components of the surgical instrument 10. Turningnow to FIGS. 21A-21B, where one example of a segmented circuit 2000comprising a plurality of circuit segments 2002 a-2002 g is illustrated.The segmented circuit 2000 comprising the plurality of circuit segments2002 a-2002 g is configured to control a powered surgical instrument,such as, for example, the surgical instrument 10 illustrated in FIGS.1-18A, without limitation. The plurality of circuit segments 2002 a-2002g is configured to control one or more operations of the poweredsurgical instrument 10. A safety processor segment 2002 a (Segment 1)comprises a safety processor 2004. A primary processor segment 2002 b(Segment 2) comprises a primary processor 2006. The safety processor2004 and/or the primary processor 2006 are configured to interact withone or more additional circuit segments 2002 c-2002 g to controloperation of the powered surgical instrument 10. The primary processor2006 comprises a plurality of inputs coupled to, for example, one ormore circuit segments 2002 c-2002 g, a battery 2008, and/or a pluralityof switches 2058 a-2070. The segmented circuit 2000 may be implementedby any suitable circuit, such as, for example, a printed circuit boardassembly (PCBA) within the powered surgical instrument 10. It should beunderstood that the term processor as used herein includes anymicroprocessor, microcontroller, or other basic computing device thatincorporates the functions of a computer's central processing unit (CPU)on an integrated circuit or at most a few integrated circuits. Theprocessor is a multipurpose, programmable device that accepts digitaldata as input, processes it according to instructions stored in itsmemory, and provides results as output. It is an example of sequentialdigital logic, as it has internal memory. Processors operate on numbersand symbols represented in the binary numeral system.

In one aspect, the main processor 2006 may be any single core ormulticore processor such as those known under the trade name ARM Cortexby Texas Instruments. In one example, the safety processor 2004 may be asafety microcontroller platform comprising two microcontroller-basedfamilies such as TMS570 and RM4x known under the trade name Hercules ARMCortex R4, also by Texas Instruments. Nevertheless, other suitablesubstitutes for microcontrollers and safety processor may be employed,without limitation. In one example, the safety processor 2004 may beconfigured specifically for IEC 61508 and ISO 26262 safety criticalapplications, among others, to provide advanced integrated safetyfeatures while delivering scalable performance, connectivity, and memoryoptions.

In certain instances, the main processor 2006 may be an LM 4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle SRAM, internal ROM loadedwith StellarisWare® software, 2 KB EEPROM, one or more PWM modules, oneor more QEI analog, one or more 12-bit ADC with 12 analog inputchannels, among other features that are readily available for theproduct datasheet. Other processors may be readily substituted and,accordingly, the present disclosure should not be limited in thiscontext.

In one aspect, the segmented circuit 2000 comprises an accelerationsegment 2002 c (Segment 3). The acceleration segment 2002 c comprises anacceleration sensor 2022. The acceleration sensor 2022 may comprise, forexample, an accelerometer. The acceleration sensor 2022 is configured todetect movement or acceleration of the powered surgical instrument 10.In some examples, input from the acceleration sensor 2022 is used, forexample, to transition to and from a sleep mode, identify an orientationof the powered surgical instrument, and/or identify when the surgicalinstrument has been dropped. In some examples, the acceleration segment2002 c is coupled to the safety processor 2004 and/or the primaryprocessor 2006.

In one aspect, the segmented circuit 2000 comprises a display segment2002 d (Segment 4). The display segment 2002 d comprises a displayconnector 2024 coupled to the primary processor 2006. The displayconnector 2024 couples the primary processor 2006 to a display 2028through one or more display driver integrated circuits 2026. The displaydriver integrated circuits 2026 may be integrated with the display 2028and/or may be located separately from the display 2028. The display 2028may comprise any suitable display, such as, for example, an organiclight-emitting diode (OLED) display, a liquid-crystal display (LCD),and/or any other suitable display. In some examples, the display segment2002 d is coupled to the safety processor 2004.

In some aspects, the segmented circuit 2000 comprises a shaft segment2002 e (Segment 5). The shaft segment 2002 e comprises one or morecontrols for a shaft 2004 coupled to the surgical instrument 10 and/orone or more controls for an end effector 2006 coupled to the shaft 2004.The shaft segment 2002 e comprises a shaft connector 2030 configured tocouple the primary processor 2006 to a shaft PCBA 2031. The shaft PCBA2031 comprises a first articulation switch 2036, a second articulationswitch 2032, and a shaft PCBA EEPROM 2034. In some examples, the shaftPCBA EEPROM 2034 comprises one or more parameters, routines, and/orprograms specific to the shaft 2004 and/or the shaft PCBA 2031. Theshaft PCBA 2031 may be coupled to the shaft 2004 and/or integral withthe surgical instrument 10. In some examples, the shaft segment 2002 ecomprises a second shaft EEPROM 2038. The second shaft EEPROM 2038comprises a plurality of algorithms, routines, parameters, and/or otherdata corresponding to one or more shafts 2004 and/or end effectors 2006which may be interfaced with the powered surgical instrument 10.

In some aspects, the segmented circuit 2000 comprises a position encodersegment 2002 f (Segment 6). The position encoder segment 2002 fcomprises one or more magnetic rotary position encoders 2040 a-2040 b.The one or more magnetic rotary position encoders 2040 a-2040 b areconfigured to identify the rotational position of a motor 2048, a shaft2004, and/or an end effector 2006 of the surgical instrument 10. In someexamples, the magnetic rotary position encoders 2040 a-2040 b may becoupled to the safety processor 2004 and/or the primary processor 2006.

In some aspects, the segmented circuit 2000 comprises a motor segment2002 g (Segment 7). The motor segment 2002 g comprises a motor 2048configured to control one or more movements of the powered surgicalinstrument 10. The motor 2048 is coupled to the primary processor 2006by an H-Bridge driver 2042 and one or more H-bridge field-effecttransistors (FETs) 2044. The H-bridge FETs 2044 are coupled to thesafety processor 2004. A motor current sensor 2046 is coupled in serieswith the motor 2048 to measure the current draw of the motor 2048. Themotor current sensor 2046 is in signal communication with the primaryprocessor 2006 and/or the safety processor 2004. In some examples, themotor 2048 is coupled to a motor electromagnetic interference (EMI)filter 2050.

In some aspects, the segmented circuit 2000 comprises a power segment2002 h (Segment 8). A battery 2008 is coupled to the safety processor2004, the primary processor 2006, and one or more of the additionalcircuit segments 2002 c-2002 g. The battery 2008 is coupled to thesegmented circuit 2000 by a battery connector 2010 and a current sensor2012. The current sensor 2012 is configured to measure the total currentdraw of the segmented circuit 2000. In some examples, one or morevoltage converters 2014 a, 2014 b, 2016 are configured to providepredetermined voltage values to one or more circuit segments 2002 a-2002g. For example, in some examples, the segmented circuit 2000 maycomprise 3.3V voltage converters 2014 a-2014 b and/or 5V voltageconverters 2016. A boost converter 2018 is configured to provide a boostvoltage up to a predetermined amount, such as, for example, up to 13V.The boost converter 2018 is configured to provide additional voltageand/or current during power intensive operations and prevent brownout orlow-power conditions.

In some aspects, the safety segment 2002 a comprises a motor powerinterrupt 2020. The motor power interrupt 2020 is coupled between thepower segment 2002 h and the motor segment 2002 g. The safety segment2002 a is configured to interrupt power to the motor segment 2002 g whenan error or fault condition is detected by the safety processor 2004and/or the primary processor 2006 as discussed in more detail herein.Although the circuit segments 2002 a-2002 g are illustrated with allcomponents of the circuit segments 2002 a-2002 h located in physicalproximity, one skilled in the art will recognize that a circuit segment2002 a-2002 h may comprise components physically and/or electricallyseparate from other components of the same circuit segment 2002 a-2002g. In some examples, one or more components may be shared between two ormore circuit segments 2002 a-2002 g.

In some aspects, a plurality of switches 2056-2070 are coupled to thesafety processor 2004 and/or the primary processor 2006. The pluralityof switches 2056-2070 may be configured to control one or moreoperations of the surgical instrument 10, control one or more operationsof the segmented circuit 2000, and/or indicate a status of the surgicalinstrument 10. For example, a bail-out door switch 2056 is configured toindicate the status of a bail-out door. A plurality of articulationswitches, such as, for example, a left side articulation left switch2058 a, a left side articulation right switch 2060 a, a left sidearticulation center switch 2062 a, a right side articulation left switch2058 b, a right side articulation right switch 2060 b, and a right sidearticulation center switch 2062 b are configured to control articulationof a shaft 2004 and/or an end effector 2006. A left side reverse switch2064 a and a right side reverse switch 2064 b are coupled to the primaryprocessor 2006. In some examples, the left side switches comprising theleft side articulation left switch 2058 a, the left side articulationright switch 2060 a, the left side articulation center switch 2062 a,and the left side reverse switch 2064 a are coupled to the primaryprocessor 2006 by a left flex connector 2072 a. The right side switchescomprising the right side articulation left switch 2058 b, the rightside articulation right switch 2060 b, the right side articulationcenter switch 2062 b, and the right side reverse switch 2064 b arecoupled to the primary processor 2006 by a right flex connector 2072 b.In some examples, a firing switch 2066, a clamp release switch 2068, anda shaft engaged switch 2070 are coupled to the primary processor 2006.

In some aspects, the plurality of switches 2056-2070 may comprise, forexample, a plurality of handle controls mounted to a handle of thesurgical instrument 10, a plurality of indicator switches, and/or anycombination thereof. In various examples, the plurality of switches2056-2070 allow a surgeon to manipulate the surgical instrument, providefeedback to the segmented circuit 2000 regarding the position and/oroperation of the surgical instrument, and/or indicate unsafe operationof the surgical instrument 10. In some examples, additional or fewerswitches may be coupled to the segmented circuit 2000, one or more ofthe switches 2056-2070 may be combined into a single switch, and/orexpanded to multiple switches. For example, in one example, one or moreof the left side and/or right side articulation switches 2058 a-2064 bmay be combined into a single multi-position switch.

In one aspect, the safety processor 2004 is configured to implement awatchdog function, among other safety operations. The safety processor2004 and the primary processor 2006 of the segmented circuit 2000 are insignal communication. A microprocessor alive heartbeat signal isprovided at output 2096. The acceleration segment 2002 c comprises anaccelerometer 2022 configured to monitor movement of the surgicalinstrument 10. In various examples, the accelerometer 2022 may be asingle, double, or triple axis accelerometer. The accelerometer 2022 maybe employed to measures proper acceleration that is not necessarily thecoordinate acceleration (rate of change of velocity). Instead, theaccelerometer sees the acceleration associated with the phenomenon ofweight experienced by a test mass at rest in the frame of reference ofthe accelerometer 2022. For example, the accelerometer 2022 at rest onthe surface of the earth will measure an acceleration g=9.8 m/s²(gravity) straight upwards, due to its weight. Another type ofacceleration that accelerometer 2022 can measure is g-forceacceleration. In various other examples, the accelerometer 2022 maycomprise a single, double, or triple axis accelerometer. Further, theacceleration segment 2002 c may comprise one or more inertial sensors todetect and measure acceleration, tilt, shock, vibration, rotation, andmultiple degrees-of-freedom (DoF). A suitable inertial sensor maycomprise an accelerometer (single, double, or triple axis), amagnetometer to measure a magnetic field in space such as the earth'smagnetic field, and/or a gyroscope to measure angular velocity.

In one aspect, the safety processor 2004 is configured to implement awatchdog function with respect to one or more circuit segments 2002c-2002 h, such as, for example, the motor segment 2002 g. In thisregards, the safety processor 2004 employs the watchdog function todetect and recover from malfunctions of the primary processor 2006.During normal operation, the safety processor 2004 monitors for hardwarefaults or program errors of the primary processor 2004 and to initiatecorrective action or actions. The corrective actions may include placingthe primary processor 2006 in a safe state and restoring normal systemoperation. In one example, the safety processor 2004 is coupled to atleast a first sensor. The first sensor measures a first property of thesurgical instrument 10 (FIGS. 1-4). In some examples, the safetyprocessor 2004 is configured to compare the measured property of thesurgical instrument 10 to a predetermined value. For example, in oneexample, a motor sensor 2040 a is coupled to the safety processor 2004.The motor sensor 2040 a provides motor speed and position information tothe safety processor 2004. The safety processor 2004 monitors the motorsensor 2040 a and compares the value to a maximum speed and/or positionvalue and prevents operation of the motor 2048 above the predeterminedvalues. In some examples, the predetermined values are calculated basedon real-time speed and/or position of the motor 2048, calculated fromvalues supplied by a second motor sensor 2040 b in communication withthe primary processor 2006, and/or provided to the safety processor 2004from, for example, a memory module coupled to the safety processor 2004.

In some aspects, a second sensor is coupled to the primary processor2006. The second sensor is configured to measure the first physicalproperty. The safety processor 2004 and the primary processor 2006 areconfigured to provide a signal indicative of the value of the firstsensor and the second sensor respectively. When either the safetyprocessor 2004 or the primary processor 2006 indicates a value outsideof an acceptable range, the segmented circuit 2000 prevents operation ofat least one of the circuit segments 2002 c-2002 h, such as, forexample, the motor segment 2002 g. For example, in the exampleillustrated in FIGS. 21A-21B, the safety processor 2004 is coupled to afirst motor position sensor 2040 a and the primary processor 2006 iscoupled to a second motor position sensor 2040 b. The motor positionsensors 2040 a, 2040 b may comprise any suitable motor position sensor,such as, for example, a magnetic angle rotary input comprising a sineand cosine output. The motor position sensors 2040 a, 2040 b providerespective signals to the safety processor 2004 and the primaryprocessor 2006 indicative of the position of the motor 2048.

The safety processor 2004 and the primary processor 2006 generate anactivation signal when the values of the first motor sensor 2040 a andthe second motor sensor 2040 b are within a predetermined range. Wheneither the primary processor 2006 or the safety processor 2004 to detecta value outside of the predetermined range, the activation signal isterminated and operation of at least one circuit segment 2002 c-2002 h,such as, for example, the motor segment 2002 g, is interrupted and/orprevented. For example, in some examples, the activation signal from theprimary processor 2006 and the activation signal from the safetyprocessor 2004 are coupled to an AND gate. The AND gate is coupled to amotor power switch 2020. The AND gate maintains the motor power switch2020 in a closed, or on, position when the activation signal from boththe safety processor 2004 and the primary processor 2006 are high,indicating a value of the motor sensors 2040 a, 2040 b within thepredetermined range. When either of the motor sensors 2040 a, 2040 bdetect a value outside of the predetermined range, the activation signalfrom that motor sensor 2040 a, 2040 b is set low, and the output of theAND gate is set low, opening the motor power switch 2020. In someexamples, the value of the first sensor 2040 a and the second sensor2040 b is compared, for example, by the safety processor 2004 and/or theprimary processor 2006. When the values of the first sensor and thesecond sensor are different, the safety processor 2004 and/or theprimary processor 2006 may prevent operation of the motor segment 2002g.

In some aspects, the safety processor 2004 receives a signal indicativeof the value of the second sensor 2040 b and compares the second sensorvalue to the first sensor value. For example, in one aspect, the safetyprocessor 2004 is coupled directly to a first motor sensor 2040 a. Asecond motor sensor 2040 b is coupled to a primary processor 2006, whichprovides the second motor sensor 2040 b value to the safety processor2004, and/or coupled directly to the safety processor 2004. The safetyprocessor 2004 compares the value of the first motor sensor 2040 to thevalue of the second motor sensor 2040 b. When the safety processor 2004detects a mismatch between the first motor sensor 2040 a and the secondmotor sensor 2040 b, the safety processor 2004 may interrupt operationof the motor segment 2002 g, for example, by cutting power to the motorsegment 2002 g.

In some aspects, the safety processor 2004 and/or the primary processor2006 is coupled to a first sensor 2040 a configured to measure a firstproperty of a surgical instrument and a second sensor 2040 b configuredto measure a second property of the surgical instrument. The firstproperty and the second property comprise a predetermined relationshipwhen the surgical instrument is operating normally. The safety processor2004 monitors the first property and the second property. When a valueof the first property and/or the second property inconsistent with thepredetermined relationship is detected, a fault occurs. When a faultoccurs, the safety processor 2004 takes at least one action, such as,for example, preventing operation of at least one of the circuitsegments, executing a predetermined operation, and/or resetting theprimary processor 2006. For example, the safety processor 2004 may openthe motor power switch 2020 to cut power to the motor circuit segment2002 g when a fault is detected.

In one aspect, the safety processor 2004 is configured to execute anindependent control algorithm. In operation, the safety processor 2004monitors the segmented circuit 2000 and is configured to control and/oroverride signals from other circuit components, such as, for example,the primary processor 2006, independently. The safety processor 2004 mayexecute a preprogrammed algorithm and/or may be updated or programmed onthe fly during operation based on one or more actions and/or positionsof the surgical instrument 10. For example, in one example, the safetyprocessor 2004 is reprogrammed with new parameters and/or safetyalgorithms each time a new shaft and/or end effector is coupled to thesurgical instrument 10. In some examples, one or more safety valuesstored by the safety processor 2004 are duplicated by the primaryprocessor 2006. Two-way error detection is performed to ensure valuesand/or parameters stored by either of the processors 2004, 2006 arecorrect.

In some aspects, the safety processor 2004 and the primary processor2006 implement a redundant safety check. The safety processor 2004 andthe primary processor 2006 provide periodic signals indicating normaloperation. For example, during operation, the safety processor 2004 mayindicate to the primary processor 2006 that the safety processor 2004 isexecuting code and operating normally. The primary processor 2006 may,likewise, indicate to the safety processor 2004 that the primaryprocessor 2006 is executing code and operating normally. In someexamples, communication between the safety processor 2004 and theprimary processor 2006 occurs at a predetermined interval. Thepredetermined interval may be constant or may be variable based on thecircuit state and/or operation of the surgical instrument 10.

FIG. 22 illustrates one example of a power assembly 2100 comprising ausage cycle circuit 2102 configured to monitor a usage cycle count ofthe power assembly 2100. The power assembly 2100 may be coupled to asurgical instrument 2110. The usage cycle circuit 2102 comprises aprocessor 2104 and a use indicator 2106. The use indicator 2106 isconfigured to provide a signal to the processor 2104 to indicate a useof the battery back 2100 and/or a surgical instrument 2110 coupled tothe power assembly 2100. A “use” may comprise any suitable action,condition, and/or parameter such as, for example, changing a modularcomponent of a surgical instrument 2110, deploying or firing adisposable component coupled to the surgical instrument 2110, deliveringelectrosurgical energy from the surgical instrument 2110, reconditioningthe surgical instrument 2110 and/or the power assembly 2100, exchangingthe power assembly 2100, recharging the power assembly 2100, and/orexceeding a safety limitation of the surgical instrument 2110 and/or thebattery back 2100.

In some instances, a usage cycle, or use, is defined by one or morepower assembly 2100 parameters. For example, in one instance, a usagecycle comprises using more than 5% of the total energy available fromthe power assembly 2100 when the power assembly 2100 is at a full chargelevel. In another instance, a usage cycle comprises a continuous energydrain from the power assembly 2100 exceeding a predetermined time limit.For example, a usage cycle may correspond to five minutes of continuousand/or total energy draw from the power assembly 2100. In someinstances, the power assembly 2100 comprises a usage cycle circuit 2102having a continuous power draw to maintain one or more components of theusage cycle circuit 2102, such as, for example, the use indicator 2106and/or a counter 2108, in an active state.

The processor 2104 maintains a usage cycle count. The usage cycle countindicates the number of uses detected by the use indicator 2106 for thepower assembly 2100 and/or the surgical instrument 2110. The processor2104 may increment and/or decrement the usage cycle count based on inputfrom the use indicator 2106. The usage cycle count is used to controlone or more operations of the power assembly 2100 and/or the surgicalinstrument 2110. For example, in some instances, a power assembly 2100is disabled when the usage cycle count exceeds a predetermined usagelimit Although the instances discussed herein are discussed with respectto incrementing the usage cycle count above a predetermined usage limit,those skilled in the art will recognize that the usage cycle count maystart at a predetermined amount and may be decremented by the processor2104. In this instance, the processor 2104 initiates and/or prevents oneor more operations of the power assembly 2100 when the usage cycle countfalls below a predetermined usage limit.

The usage cycle count is maintained by a counter 2108. The counter 2108comprises any suitable circuit, such as, for example, a memory module,an analog counter, and/or any circuit configured to maintain a usagecycle count. In some instances, the counter 2108 is formed integrallywith the processor 2104. In other instances, the counter 2108 comprisesa separate component, such as, for example, a solid state memory module.In some instances, the usage cycle count is provided to a remote system,such as, for example, a central database. The usage cycle count istransmitted by a communications module 2112 to the remote system. Thecommunications module 2112 is configured to use any suitablecommunications medium, such as, for example, wired and/or wirelesscommunication. In some instances, the communications module 2112 isconfigured to receive one or more instructions from the remote system,such as, for example, a control signal when the usage cycle countexceeds the predetermined usage limit.

In some instances, the use indicator 2106 is configured to monitor thenumber of modular components used with a surgical instrument 2110coupled to the power assembly 2100. A modular component may comprise,for example, a modular shaft, a modular end effector, and/or any othermodular component. In some instances, the use indicator 2106 monitorsthe use of one or more disposable components, such as, for example,insertion and/or deployment of a staple cartridge within an end effectorcoupled to the surgical instrument 2110. The use indicator 2106comprises one or more sensors for detecting the exchange of one or moremodular and/or disposable components of the surgical instrument 2110.

In some instances, the use indicator 2106 is configured to monitorsingle patient surgical procedures performed while the power assembly2100 is installed. For example, the use indicator 2106 may be configuredto monitor firings of the surgical instrument 2110 while the powerassembly 2100 is coupled to the surgical instrument 2110. A firing maycorrespond to deployment of a staple cartridge, application ofelectrosurgical energy, and/or any other suitable surgical event. Theuse indicator 2106 may comprise one or more circuits for measuring thenumber of firings while the power assembly 2100 is installed. The useindicator 2106 provides a signal to the processor 2104 when a singlepatient procedure is performed and the processor 2104 increments theusage cycle count.

In some instances, the use indicator 2106 comprises a circuit configuredto monitor one or more parameters of the power source 2114, such as, forexample, a current draw from the power source 2114. The one or moreparameters of the power source 2114 correspond to one or more operationsperformable by the surgical instrument 2110, such as, for example, acutting and sealing operation. The use indicator 2106 provides the oneor more parameters to the processor 2104, which increments the usagecycle count when the one or more parameters indicate that a procedurehas been performed.

In some instances, the use indicator 2106 comprises a timing circuitconfigured to increment a usage cycle count after a predetermined timeperiod. The predetermined time period corresponds to a single patientprocedure time, which is the time required for an operator to perform aprocedure, such as, for example, a cutting and sealing procedure. Whenthe power assembly 2100 is coupled to the surgical instrument 2110, theprocessor 2104 polls the use indicator 2106 to determine when the singlepatient procedure time has expired. When the predetermined time periodhas elapsed, the processor 2104 increments the usage cycle count. Afterincrementing the usage cycle count, the processor 2104 resets the timingcircuit of the use indicator 2106.

In some instances, the use indicator 2106 comprises a time constant thatapproximates the single patient procedure time. In one example, theusage cycle circuit 2102 comprises a resistor-capacitor (RC) timingcircuit 2506. The RC timing circuit comprises a time constant defined bya resistor-capacitor pair. The time constant is defined by the values ofthe resistor and the capacitor. In one example, the usage cycle circuit2552 comprises a rechargeable battery and a clock. When the powerassembly 2100 is installed in a surgical instrument, the rechargeablebattery is charged by the power source. The rechargeable batterycomprises enough power to run the clock for at least the single patientprocedure time. The clock may comprise a real time clock, a processorconfigured to implement a time function, or any other suitable timingcircuit.

Referring still to FIG. 22, in some instances, the use indicator 2106comprises a sensor configured to monitor one or more environmentalconditions experienced by the power assembly 2100. For example, the useindicator 2106 may comprise an accelerometer. The accelerometer isconfigured to monitor acceleration of the power assembly 2100. The powerassembly 2100 comprises a maximum acceleration tolerance. Accelerationabove a predetermined threshold indicates, for example, that the powerassembly 2100 has been dropped. When the use indicator 2106 detectsacceleration above the maximum acceleration tolerance, the processor2104 increments a usage cycle count. In some instances, the useindicator 2106 comprises a moisture sensor. The moisture sensor isconfigured to indicate when the power assembly 2100 has been exposed tomoisture. The moisture sensor may comprise, for example, an immersionsensor configured to indicate when the power assembly 2100 has beenfully immersed in a cleaning fluid, a moisture sensor configured toindicate when moisture is in contact with the power assembly 2100 duringuse, and/or any other suitable moisture sensor.

In some instances, the use indicator 2106 comprises a chemical exposuresensor. The chemical exposure sensor is configured to indicate when thepower assembly 2100 has come into contact with harmful and/or dangerouschemicals. For example, during a sterilization procedure, aninappropriate chemical may be used that leads to degradation of thepower assembly 2100. The processor 2104 increments the usage cycle countwhen the use indicator 2106 detects an inappropriate chemical.

In some instances, the usage cycle circuit 2102 is configured to monitorthe number of reconditioning cycles experienced by the power assembly2100. A reconditioning cycle may comprise, for example, a cleaningcycle, a sterilization cycle, a charging cycle, routine and/orpreventative maintenance, and/or any other suitable reconditioningcycle. The use indicator 2106 is configured to detect a reconditioningcycle. For example, the use indicator 2106 may comprise a moisturesensor to detect a cleaning and/or sterilization cycle. In someinstances, the usage cycle circuit 2102 monitors the number ofreconditioning cycles experienced by the power assembly 2100 anddisables the power assembly 2100 after the number of reconditioningcycles exceeds a predetermined threshold.

The usage cycle circuit 2102 may be configured to monitor the number ofpower assembly 2100 exchanges. The usage cycle circuit 2102 incrementsthe usage cycle count each time the power assembly 2100 is exchanged.When the maximum number of exchanges is exceeded the usage cycle circuit2102 locks out the power assembly 2100 and/or the surgical instrument2110. In some instances, when the power assembly 2100 is coupled thesurgical instrument 2110, the usage cycle circuit 2102 identifies theserial number of the power assembly 2100 and locks the power assembly2100 such that the power assembly 2100 is usable only with the surgicalinstrument 2110. In some instances, the usage cycle circuit 2102increments the usage cycle each time the power assembly 2100 is removedfrom and/or coupled to the surgical instrument 2110.

In some instances, the usage cycle count corresponds to sterilization ofthe power assembly 2100. The use indicator 2106 comprises a sensorconfigured to detect one or more parameters of a sterilization cycle,such as, for example, a temperature parameter, a chemical parameter, amoisture parameter, and/or any other suitable parameter. The processor2104 increments the usage cycle count when a sterilization parameter isdetected. The usage cycle circuit 2102 disables the power assembly 2100after a predetermined number of sterilizations. In some instances, theusage cycle circuit 2102 is reset during a sterilization cycle, avoltage sensor to detect a recharge cycle, and/or any suitable sensor.The processor 2104 increments the usage cycle count when areconditioning cycle is detected. The usage cycle circuit 2102 isdisabled when a sterilization cycle is detected. The usage cycle circuit2102 is reactivated and/or reset when the power assembly 2100 is coupledto the surgical instrument 2110. In some instances, the use indicatorcomprises a zero power indicator. The zero power indicator changes stateduring a sterilization cycle and is checked by the processor 2104 whenthe power assembly 2100 is coupled to a surgical instrument 2110. Whenthe zero power indicator indicates that a sterilization cycle hasoccurred, the processor 2104 increments the usage cycle count.

A counter 2108 maintains the usage cycle count. In some instances, thecounter 2108 comprises a non-volatile memory module. The processor 2104increments the usage cycle count stored in the non-volatile memorymodule each time a usage cycle is detected. The memory module may beaccessed by the processor 2104 and/or a control circuit, such as, forexample, the control circuit 200. When the usage cycle count exceeds apredetermined threshold, the processor 2104 disables the power assembly2100. In some instances, the usage cycle count is maintained by aplurality of circuit components. For example, in one instance, thecounter 2108 comprises a resistor (or fuse) pack. After each use of thepower assembly 2100, a resistor (or fuse) is burned to an open position,changing the resistance of the resistor pack. The power assembly 2100and/or the surgical instrument 2110 reads the remaining resistance. Whenthe last resistor of the resistor pack is burned out, the resistor packhas a predetermined resistance, such as, for example, an infiniteresistance corresponding to an open circuit, which indicates that thepower assembly 2100 has reached its usage limit. In some instances, theresistance of the resistor pack is used to derive the number of usesremaining.

In some instances, the usage cycle circuit 2102 prevents further use ofthe power assembly 2100 and/or the surgical instrument 2110 when theusage cycle count exceeds a predetermined usage limit. In one instance,the usage cycle count associated with the power assembly 2100 isprovided to an operator, for example, utilizing a screen formedintegrally with the surgical instrument 2110. The surgical instrument2110 provides an indication to the operator that the usage cycle counthas exceeded a predetermined limit for the power assembly 2100, andprevents further operation of the surgical instrument 2110.

In some instances, the usage cycle circuit 2102 is configured tophysically prevent operation when the predetermined usage limit isreached. For example, the power assembly 2100 may comprise a shieldconfigured to deploy over contacts of the power assembly 2100 when theusage cycle count exceeds the predetermined usage limit. The shieldprevents recharge and use of the power assembly 2100 by covering theelectrical connections of the power assembly 2100.

In some instances, the usage cycle circuit 2102 is located at leastpartially within the surgical instrument 2110 and is configured tomaintain a usage cycle count for the surgical instrument 2110. FIG. 22illustrates one or more components of the usage cycle circuit 2102within the surgical instrument 2110 in phantom, illustrating thealternative positioning of the usage cycle circuit 2102. When apredetermined usage limit of the surgical instrument 2110 is exceeded,the usage cycle circuit 2102 disables and/or prevents operation of thesurgical instrument 2110. The usage cycle count is incremented by theusage cycle circuit 2102 when the use indicator 2106 detects a specificevent and/or requirement, such as, for example, firing of the surgicalinstrument 2110, a predetermined time period corresponding to a singlepatient procedure time, based on one or more motor parameters of thesurgical instrument 2110, in response to a system diagnostic indicatingthat one or more predetermined thresholds are met, and/or any othersuitable requirement. As discussed above, in some instances, the useindicator 2106 comprises a timing circuit corresponding to a singlepatient procedure time. In other instances, the use indicator 2106comprises one or more sensors configured to detect a specific eventand/or condition of the surgical instrument 2110.

In some instances, the usage cycle circuit 2102 is configured to preventoperation of the surgical instrument 2110 after the predetermined usagelimit is reached. In some instances, the surgical instrument 2110comprises a visible indicator to indicate when the predetermined usagelimit has been reached and/or exceeded. For example, a flag, such as ared flag, may pop-up from the surgical instrument 2110, such as from thehandle, to provide a visual indication to the operator that the surgicalinstrument 2110 has exceeded the predetermined usage limit. As anotherexample, the usage cycle circuit 2102 may be coupled to a display formedintegrally with the surgical instrument 2110. The usage cycle circuit2102 displays a message indicating that the predetermined usage limithas been exceeded. The surgical instrument 2110 may provide an audibleindication to the operator that the predetermined usage limit has beenexceeded. For example, in one instance, the surgical instrument 2110emits an audible tone when the predetermined usage limit is exceeded andthe power assembly 2100 is removed from the surgical instrument 2110.The audible tone indicates the last use of the surgical instrument 2110and indicates that the surgical instrument 2110 should be disposed orreconditioned.

In some instances, the usage cycle circuit 2102 is configured totransmit the usage cycle count of the surgical instrument 2110 to aremote location, such as, for example, a central database. The usagecycle circuit 2102 comprises a communications module 2112 configured totransmit the usage cycle count to the remote location. Thecommunications module 2112 may utilize any suitable communicationssystem, such as, for example, wired or wireless communications system.The remote location may comprise a central database configured tomaintain usage information. In some instances, when the power assembly2100 is coupled to the surgical instrument 2110, the power assembly 2100records a serial number of the surgical instrument 2110. The serialnumber is transmitted to the central database, for example, when thepower assembly 2100 is coupled to a charger. In some instances, thecentral database maintains a count corresponding to each use of thesurgical instrument 2110. For example, a bar code associated with thesurgical instrument 2110 may be scanned each time the surgicalinstrument 2110 is used. When the use count exceeds a predeterminedusage limit, the central database provides a signal to the surgicalinstrument 2110 indicating that the surgical instrument 2110 should bediscarded.

The surgical instrument 2110 may be configured to lock and/or preventoperation of the surgical instrument 2110 when the usage cycle countexceeds a predetermined usage limit. In some instances, the surgicalinstrument 2110 comprises a disposable instrument and is discarded afterthe usage cycle count exceeds the predetermined usage limit. In otherinstances, the surgical instrument 2110 comprises a reusable surgicalinstrument which may be reconditioned after the usage cycle countexceeds the predetermined usage limit. The surgical instrument 2110initiates a reversible lockout after the predetermined usage limit ismet. A technician reconditions the surgical instrument 2110 and releasesthe lockout, for example, utilizing a specialized technician keyconfigured to reset the usage cycle circuit 2102.

In some aspects, the segmented circuit 2000 is configured for sequentialstart-up. An error check is performed by each circuit segment 2002a-2002 g prior to energizing the next sequential circuit segment 2002a-2002 g. FIG. 23 illustrates one example of a process for sequentiallyenergizing a segmented circuit 2270, such as, for example, the segmentedcircuit 2000. When a battery 2008 is coupled to the segmented circuit2000, the safety processor 2004 is energized 2272. The safety processor2004 performs a self-error check 2274. When an error is detected 2276 a,the safety processor stops energizing the segmented circuit 2000 andgenerates an error code 2278 a. When no errors are detected 2276 b, thesafety processor 2004 initiates 2278 b power-up of the primary processor2006. The primary processor 2006 performs a self-error check. When noerrors are detected, the primary processor 2006 begins sequentialpower-up of each of the remaining circuit segments 2278 b. Each circuitsegment is energized and error checked by the primary processor 2006.When no errors are detected, the next circuit segment is energized 2278b. When an error is detected, the safety processor 2004 and/or theprimary process stops energizing the current segment and generates anerror 2278 a. The sequential start-up continues until all of the circuitsegments 2002 a-2002 g have been energized. In some examples, thesegmented circuit 2000 transitions from sleep mode following a similarsequential power-up process 11250.

FIG. 24 illustrates one aspect of a power segment 2302 comprising aplurality of daisy chained power converters 2314, 2316, 2318. The powersegment 2302 comprises a battery 2308. The battery 2308 is configured toprovide a source voltage, such as, for example, 12V. A current sensor2312 is coupled to the battery 2308 to monitor the current draw of asegmented circuit and/or one or more circuit segments. The currentsensor 2312 is coupled to an FET switch 2313. The battery 2308 iscoupled to one or more voltage converters 2309, 2314, 2316. An always onconverter 2309 provides a constant voltage to one or more circuitcomponents, such as, for example, a motion sensor 2322. The always onconverter 2309 comprises, for example, a 3.3V converter. The always onconverter 2309 may provide a constant voltage to additional circuitcomponents, such as, for example, a safety processor (not shown). Thebattery 2308 is coupled to a boost converter 2318. The boost converter2318 is configured to provide a boosted voltage above the voltageprovided by the battery 2308. For example, in the illustrated example,the battery 2308 provides a voltage of 12V. The boost converter 2318 isconfigured to boost the voltage to 13V. The boost converter 2318 isconfigured to maintain a minimum voltage during operation of a surgicalinstrument, for example, the surgical instrument 10 (FIGS. 1-4).Operation of a motor can result in the power provided to the primaryprocessor 2306 dropping below a minimum threshold and creating abrownout or reset condition in the primary processor 2306. The boostconverter 2318 ensures that sufficient power is available to the primaryprocessor 2306 and/or other circuit components, such as the motorcontroller 2343, during operation of the surgical instrument 10. In someexamples, the boost converter 2318 is coupled directly one or morecircuit components, such as, for example, an OLED display 2388.

The boost converter 2318 is coupled to one or more step-down convertersto provide voltages below the boosted voltage level. A first voltageconverter 2316 is coupled to the boost converter 2318 and provides afirst stepped-down voltage to one or more circuit components. In theillustrated example, the first voltage converter 2316 provides a voltageof 5V. The first voltage converter 2316 is coupled to a rotary positionencoder 2340. A FET switch 2317 is coupled between the first voltageconverter 2316 and the rotary position encoder 2340. The FET switch 2317is controlled by the processor 2306. The processor 2306 opens the FETswitch 2317 to deactivate the position encoder 2340, for example, duringpower intensive operations. The first voltage converter 2316 is coupledto a second voltage converter 2314 configured to provide a secondstepped-down voltage. The second stepped-down voltage comprises, forexample, 3.3V. The second voltage converter 2314 is coupled to aprocessor 2306. In some examples, the boost converter 2318, the firstvoltage converter 2316, and the second voltage converter 2314 arecoupled in a daisy chain configuration. The daisy chain configurationallows the use of smaller, more efficient converters for generatingvoltage levels below the boosted voltage level. The examples, however,are not limited to the particular voltage range(s) described in thecontext of this specification.

FIG. 25 illustrates one aspect of a segmented circuit 2400 configured tomaximize power available for critical and/or power intense functions.The segmented circuit 2400 comprises a battery 2408. The battery 2408 isconfigured to provide a source voltage such as, for example, 12V. Thesource voltage is provided to a plurality of voltage converters 2409,2418. An always-on voltage converter 2409 provides a constant voltage toone or more circuit components, for example, a motion sensor 2422 and asafety processor 2404. The always-on voltage converter 2409 is directlycoupled to the battery 2408. The always-on converter 2409 provides avoltage of 3.3V, for example. The examples, however, are not limited tothe particular voltage range(s) described in the context of thisspecification.

The segmented circuit 2400 comprises a boost converter 2418. The boostconverter 2418 provides a boosted voltage above the source voltageprovided by the battery 2408, such as, for example, 13V. The boostconverter 2418 provides a boosted voltage directly to one or morecircuit components, such as, for example, an OLED display 2488 and amotor controller 2443. By coupling the OLED display 2488 directly to theboost converter 2418, the segmented circuit 2400 eliminates the need fora power converter dedicated to the OLED display 2488. The boostconverter 2418 provides a boosted voltage to the motor controller 2443and the motor 2448 during one or more power intensive operations of themotor 2448, such as, for example, a cutting operation. The boostconverter 2418 is coupled to a step-down converter 2416. The step-downconverter 2416 is configured to provide a voltage below the boostedvoltage to one or more circuit components, such as, for example, 5V. Thestep-down converter 2416 is coupled to, for example, a FET switch 2451and a position encoder 2440. The FET switch 2451 is coupled to theprimary processor 2406. The primary processor 2406 opens the FET switch2451 when transitioning the segmented circuit 2400 to sleep mode and/orduring power intensive functions requiring additional voltage deliveredto the motor 2448. Opening the FET switch 2451 deactivates the positionencoder 2440 and eliminates the power draw of the position encoder 2440.The examples, however, are not limited to the particular voltagerange(s) described in the context of this specification.

The step-down converter 2416 is coupled to a linear converter 2414. Thelinear converter 2414 is configured to provide a voltage of, forexample, 3.3V. The linear converter 2414 is coupled to the primaryprocessor 2406. The linear converter 2414 provides an operating voltageto the primary processor 2406. The linear converter 2414 may be coupledto one or more additional circuit components. The examples, however, arenot limited to the particular voltage range(s) described in the contextof this specification.

The segmented circuit 2400 comprises a bailout switch 2456. The bailoutswitch 2456 is coupled to a bailout door on the surgical instrument 10.The bailout switch 2456 and the safety processor 2404 are coupled to anAND gate 2419. The AND gate 2419 provides an input to a FET switch 2413.When the bailout switch 2456 detects a bailout condition, the bailoutswitch 2456 provides a bailout shutdown signal to the AND gate 2419.When the safety processor 2404 detects an unsafe condition, such as, forexample, due to a sensor mismatch, the safety processor 2404 provides ashutdown signal to the AND gate 2419. In some examples, both the bailoutshutdown signal and the shutdown signal are high during normal operationand are low when a bailout condition or an unsafe condition is detected.When the output of the AND gate 2419 is low, the FET switch 2413 isopened and operation of the motor 2448 is prevented. In some examples,the safety processor 2404 utilizes the shutdown signal to transition themotor 2448 to an off state in sleep mode. A third input to the FETswitch 2413 is provided by a current sensor 2412 coupled to the battery2408. The current sensor 2412 monitors the current drawn by the circuit2400 and opens the FET switch 2413 to shut-off power to the motor 2448when an electrical current above a predetermined threshold is detected.The FET switch 2413 and the motor controller 2443 are coupled to a bankof FET switches 2445 configured to control operation of the motor 2448.

A motor current sensor 2446 is coupled in series with the motor 2448 toprovide a motor current sensor reading to a current monitor 2447. Thecurrent monitor 2447 is coupled to the primary processor 2406. Thecurrent monitor 2447 provides a signal indicative of the current draw ofthe motor 2448. The primary processor 2406 may utilize the signal fromthe motor current 2447 to control operation of the motor, for example,to ensure the current draw of the motor 2448 is within an acceptablerange, to compare the current draw of the motor 2448 to one or moreother parameters of the circuit 2400 such as, for example, the positionencoder 2440, and/or to determine one or more parameters of a treatmentsite. In some examples, the current monitor 2447 may be coupled to thesafety processor 2404.

In some aspects, actuation of one or more handle controls, such as, forexample, a firing trigger, causes the primary processor 2406 to decreasepower to one or more components while the handle control is actuated.For example, in one example, a firing trigger controls a firing strokeof a cutting member. The cutting member is driven by the motor 2448.Actuation of the firing trigger results in forward operation of themotor 2448 and advancement of the cutting member. During firing, theprimary processor 2406 closes the FET switch 2451 to remove power fromthe position encoder 2440. The deactivation of one or more circuitcomponents allows higher power to be delivered to the motor 2448. Whenthe firing trigger is released, full power is restored to thedeactivated components, for example, by closing the FET switch 2451 andreactivating the position encoder 2440.

In some aspects, the safety processor 2404 controls operation of thesegmented circuit 2400. For example, the safety processor 2404 mayinitiate a sequential power-up of the segmented circuit 2400, transitionof the segmented circuit 2400 to and from sleep mode, and/or mayoverride one or more control signals from the primary processor 2406.For example, in the illustrated example, the safety processor 2404 iscoupled to the step-down converter 2416. The safety processor 2404controls operation of the segmented circuit 2400 by activating ordeactivating the step-down converter 2416 to provide power to theremainder of the segmented circuit 2400.

FIG. 26 illustrates one aspect of a power system 2500 comprising aplurality of daisy chained power converters 2514, 2516, 2518 configuredto be sequentially energized. The plurality of daisy chained powerconverters 2514, 2516, 2518 may be sequentially activated by, forexample, a safety processor during initial power-up and/or transitionfrom sleep mode. The safety processor may be powered by an independentpower converter (not shown). For example, in one example, when a batteryvoltage V_(BATT) is coupled to the power system 2500 and/or anaccelerometer detects movement in sleep mode, the safety processorinitiates a sequential start-up of the daisy chained power converters2514, 2516, 2518. The safety processor activates the 13V boost section2518. The boost section 2518 is energized and performs a self-check. Insome examples, the boost section 2518 comprises an integrated circuit2520 configured to boost the source voltage and to perform a self check.A diode D prevents power-up of a 5V supply section 2516 until the boostsection 2518 has completed a self-check and provided a signal to thediode D indicating that the boost section 2518 did not identify anyerrors. In some examples, this signal is provided by the safetyprocessor. The examples, however, are not limited to the particularvoltage range(s) described in the context of this specification.

The 5V supply section 2516 is sequentially powered-up after the boostsection 2518. The 5V supply section 2516 performs a self-check duringpower-up to identify any errors in the 5V supply section 2516. The 5Vsupply section 2516 comprises an integrated circuit 2515 configured toprovide a step-down voltage from the boost voltage and to perform anerror check. When no errors are detected, the 5V supply section 2516completes sequential power-up and provides an activation signal to the3.3V supply section 2514. In some examples, the safety processorprovides an activation signal to the 3.3V supply section 2514. The 3.3Vsupply section comprises an integrated circuit 2513 configured toprovide a step-down voltage from the 5V supply section 2516 and performa self-error check during power-up. When no errors are detected duringthe self-check, the 3.3V supply section 2514 provides power to theprimary processor. The primary processor is configured to sequentiallyenergize each of the remaining circuit segments. By sequentiallyenergizing the power system 2500 and/or the remainder of a segmentedcircuit, the power system 2500 reduces error risks, allows forstabilization of voltage levels before loads are applied, and preventslarge current draws from all hardware being turned on simultaneously inan uncontrolled manner. The examples, however, are not limited to theparticular voltage range(s) described in the context of thisspecification.

In one aspect, the power system 2500 comprises an over voltageidentification and mitigation circuit. The over voltage identificationand mitigation circuit is configured to detect a monopolar returncurrent in the surgical instrument and interrupt power from the powersegment when the monopolar return current is detected. The over voltageidentification and mitigation circuit is configured to identify groundfloatation of the power system. The over voltage identification andmitigation circuit comprises a metal oxide varistor. The over voltageidentification and mitigation circuit comprises at least one transientvoltage suppression diode.

FIG. 27 illustrates one aspect of a segmented circuit 2600 comprising anisolated control section 2602. The isolated control section 2602isolates control hardware of the segmented circuit 2600 from a powersection (not shown) of the segmented circuit 2600. The control section2602 comprises, for example, a primary processor 2606, a safetyprocessor (not shown), and/or additional control hardware, for example,a FET Switch 2617. The power section comprises, for example, a motor, amotor driver, and/or a plurality of motor MOSFETS. The isolated controlsection 2602 comprises a charging circuit 2603 and a rechargeablebattery 2608 coupled to a 5V power converter 2616. The charging circuit2603 and the rechargeable battery 2608 isolate the primary processor2606 from the power section. In some examples, the rechargeable battery2608 is coupled to a safety processor and any additional supporthardware. Isolating the control section 2602 from the power sectionallows the control section 2602, for example, the primary processor2606, to remain active even when main power is removed, provides afilter, through the rechargeable battery 2608, to keep noise out of thecontrol section 2602, isolates the control section 2602 from heavyswings in the battery voltage to ensure proper operation even duringheavy motor loads, and/or allows for real-time operating system (RTOS)to be used by the segmented circuit 2600. In some examples, therechargeable battery 2608 provides a stepped-down voltage to the primaryprocessor, such as, for example, 3.3V. The examples, however, are notlimited to the particular voltage range(s) described in the context ofthis specification.

FIGS. 28A and 28B illustrate another aspect of a control circuit 3000configured to control the powered surgical instrument 10, illustrated inFIGS. 1-18A. As shown in FIGS. 18A, 28B, the handle assembly 14 mayinclude a motor 3014 which can be controlled by a motor driver 3015 andcan be employed by the firing system of the surgical instrument 10. Invarious forms, the motor 3014 may be a DC brushed driving motor having amaximum rotation of, approximately, 25,000 RPM, for example. In otherarrangements, the motor 3014 may include a brushless motor, a cordlessmotor, a synchronous motor, a stepper motor, or any other suitableelectric motor. In certain circumstances, the motor driver 3015 maycomprise an H-Bridge FETs 3019, as illustrated in FIGS. 28A and 28B, forexample. The motor 3014 can be powered by a power assembly 3006, whichcan be releasably mounted to the handle assembly 14. The power assembly3006 is configured to supply control power to the surgical instrument10. The power assembly 3006 may comprise a battery which may include anumber of battery cells connected in series that can be used as thepower source to power the surgical instrument 10. In such configuration,the power assembly 3006 may be referred to as a battery pack. In certaincircumstances, the battery cells of the power assembly 3006 may bereplaceable and/or rechargeable. In at least one example, the batterycells can be Lithium-Ion batteries which can be separably couplable tothe power assembly 3006.

Examples of drive systems and closure systems that are suitable for usewith the surgical instrument 10 are disclosed in U.S. Provisional PatentApplication Ser. No. 61/782,866, entitled CONTROL SYSTEM OF A SURGICALINSTRUMENT, and filed Mar. 14, 2013, the entire disclosure of which isincorporated by reference herein in its entirety. For example, theelectric motor 3014 can include a rotatable shaft (not shown) that mayoperably interface with a gear reducer assembly that can be mounted inmeshing engagement with a set, or rack, of drive teeth on alongitudinally-movable drive member. In use, a voltage polarity providedby the battery can operate the electric motor 3014 to drive thelongitudinally-movable drive member to effectuate the end effector 300.For example, the motor 3014 can be configured to drive thelongitudinally-movable drive member to advance a firing mechanism tofire staples into tissue captured by the end effector 300 from a staplecartridge assembled with the end effector 300 and/or advance a cuttingmember to cut tissue captured by the end effector 300, for example.

As illustrated in FIGS. 28A and 28B and as described below in greaterdetail, the power assembly 3006 may include a power managementcontroller which can be configured to modulate the power output of thepower assembly 3006 to deliver a first power output to power the motor3014 to advance the cutting member while the interchangeable shaft 200is coupled to the handle assembly 14 (FIG. 1) and to deliver a secondpower output to power the motor 3014 to advance the cutting member whilethe interchangeable shaft assembly 200 is coupled to the handle assembly14, for example. Such modulation can be beneficial in avoidingtransmission of excessive power to the motor 3014 beyond therequirements of an interchangeable shaft assembly that is coupled to thehandle assembly 14.

In certain circumstances, the interface 3024 can facilitate transmissionof the one or more communication signals between the power managementcontroller 3016 and the shaft assembly controller 3022 by routing suchcommunication signals through a main controller 3017 residing in thehandle assembly 14 (FIG. 1), for example. In other circumstances, theinterface 3024 can facilitate a direct line of communication between thepower management controller 3016 and the shaft assembly controller 3022through the handle assembly 14 while the shaft assembly 200 (FIG. 1) andthe power assembly 3006 are coupled to the handle assembly 14.

In one instance, the main microcontroller 3017 may be any single core ormulticore processor such as those known under the trade name ARM Cortexby Texas Instruments. In one instance, the surgical instrument 10 (FIGS.1-4) may comprise a power management controller 3016 such as, forexample, a safety microcontroller platform comprising twomicrocontroller-based families such as TMS570 and RM4x known under thetrade name Hercules ARM Cortex R4, also by Texas Instruments.Nevertheless, other suitable substitutes for microcontrollers and safetyprocessor may be employed, without limitation. In one instance, thesafety processor 2004 (FIG. 21A) may be configured specifically for IEC61508 and ISO 26262 safety critical applications, among others, toprovide advanced integrated safety features while delivering scalableperformance, connectivity, and memory options.

In certain instances, the microcontroller 3017 may be an LM 4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available for the productdatasheet. The present disclosure should not be limited in this context.

FIG. 29 is a block diagram the surgical instrument of FIG. 1illustrating interfaces between the handle assembly 14 (FIG. 1) and thepower assembly and between the handle assembly 14 and theinterchangeable shaft assembly. As shown in FIG. 29, the power assembly3006 may include a power management circuit 3034 which may comprise thepower management controller 3016, a power modulator 3038, and a currentsense circuit 3036. The power management circuit 3034 can be configuredto modulate power output of the battery 3007 based on the powerrequirements of the shaft assembly 200 (FIG. 1) while the shaft assembly200 and the power assembly 3006 are coupled to the handle assembly 14.For example, the power management controller 3016 can be programmed tocontrol the power modulator 3038 of the power output of the powerassembly 3006 and the current sense circuit 3036 can be employed tomonitor power output of the power assembly 3006 to provide feedback tothe power management controller 3016 about the power output of thebattery 3007 so that the power management controller 3016 may adjust thepower output of the power assembly 3006 to maintain a desired output.

It is noteworthy that the power management controller 3016 and/or theshaft assembly controller 3022 each may comprise one or more processorsand/or memory units which may store a number of software modules.Although certain modules and/or blocks of the surgical instrument 14(FIG. 1) may be described by way of example, it can be appreciated thata greater or lesser number of modules and/or blocks may be used.Further, although various instances may be described in terms of modulesand/or blocks to facilitate description, such modules and/or blocks maybe implemented by one or more hardware components, e.g., processors,Digital Signal Processors (DSPs), Programmable Logic Devices (PLDs),Application Specific Integrated Circuits (ASICs), circuits, registersand/or software components, e.g., programs, subroutines, logic and/orcombinations of hardware and software components.

In certain instances, the surgical instrument 10 (FIGS. 1-4) maycomprise an output device 3042 which may include one or more devices forproviding a sensory feedback to a user. Such devices may comprise, forexample, visual feedback devices (e.g., an LCD display screen, LEDindicators), audio feedback devices (e.g., a speaker, a buzzer) ortactile feedback devices (e.g., haptic actuators). In certaincircumstances, the output device 3042 may comprise a display 3043 whichmay be included in the handle assembly 14 (FIG. 1). The shaft assemblycontroller 3022 and/or the power management controller 3016 can providefeedback to a user of the surgical instrument 10 through the outputdevice 3042. The interface 3024 can be configured to connect the shaftassembly controller 3022 and/or the power management controller 3016 tothe output device 3042. The reader will appreciate that the outputdevice 3042 can instead be integrated with the power assembly 3006. Insuch circumstances, communication between the output device 3042 and theshaft assembly controller 3022 may be accomplished through the interface3024 while the shaft assembly 200 is coupled to the handle assembly 14.

Having described a surgical instrument 10 (FIGS. 1-4) and variouscontrol circuits 2000, 3000 for controlling the operation thereof, thedisclosure now turns to various specific configurations of the surgicalinstrument 10 and control circuits 2000 (or 3000).

In various aspects, the present disclosure provides an instrument 10 (asdescribed in connection with FIGS. 1-29) configured to provide rate andcontrol feedback to the surgeon. In one example, the instrument 10(FIGS. 1-4) comprises an energy device to provide rate/impedancefeedback. In another example, the instrument 10 provides time dependencysuch as time between steps and/or rate of firing. In another example,the instrument 10 is configured with a display that the surgeon canmonitor for error resolution. In one implementation, the display may bea flexible roll up display is contained within handle (no externaldisplay) in the event of failure user unrolls display to determine stepsto release.

The present disclosure provides a novel feedback system for surgicalinstruments to enable the surgeon to balance the motor controlled speedof knife actuation with the thickness and stiffness of the tissuegrasped between the jaw members of the end effector such as the anviland the staple cartridge. The present technique for adjusting the knifeactuation speed based on the thickness of the tissue and tissue flow canimprove the consistency of staple formation to form a stapled seal.

Accordingly, the present disclosure provides the surgeon a feedbackmechanism on the shaft or the handle of the endosurgical device. Thefeedback comprises a combination of the speed of the advancement of theknife, the tissue compression (impedance), the tissue gap (d), and forceto advance (motor current draw). This combination can be displayed on anindicator comprising multiple zones, such as 5-9 zones, for example,with the mid zone indicating the most ideal speed for the force andtissue compression being handled. The more compression the slower thespeed to keep the indicator balanced in the center. This would provide asurgeon a repeatable relative measure to judge thickness and tissue flowand the surgeon could then decide how far out of balance theendosurgical device can be operated within certain conditions in orderto achieve overall good results. The present feedback mechanism alsowould provide the surgeon a good evaluation when the tissue and/orfiring conditions are out of the ordinary to enable the surgeon toproceed cautiously with the operation during that particular firing. Thefeedback mechanism also can enable the surgeon to learn the besttechnique for firing the endosurgical device with limited to no inservicing.

Turning to the figures, FIG. 30 illustrates a surgical instrument 9010.The surgical instrument 9010 is similar in many respects to othersurgical instruments described in the present disclosure. For example,the surgical instrument 9010 is similarly constructed and equipped asthe motor-driven surgical cutting and fastening instrument 10 describedin connection with FIGS. 1-29. Therefore, for conciseness and claritythe details of operation and construction will not be repeated here.Accordingly, the surgical instrument 9010, like other surgicalinstruments described in the present disclosure, comprises an endeffector 9012. In the example illustrated in FIGS. 30-31, the endeffector 9012 comprises a first jaw member, or anvil, 9014 pivotallycoupled to a second jaw member 9016 to capture tissue between the firstjaw member 9014 and the second jaw member 9016. The second jaw member9016 is configured to receive a staple cartridge 9018 therein. Thestaple cartridge 9018 comprises a plurality of staples 9042. Theplurality of staples 9402 is deployable from the staple cartridge 9018during a surgical operation.

In alternative aspects, the end effector 9012 can be configured to sealtissue captured between the first jaw member 9014 and the second jawmember 9016. For example, the first jaw member 9014 and the second jawmember 9016 may each include an electrically conductive member. Theelectrically conductive members may cooperate to transmit energy throughtissue captured therebetween to treat and/or seal the tissue. A powersource such as, for example, a battery can be configured to provide theenergy.

In certain instances, as illustrated in FIG. 30, the surgical instrument9010 can be a motor-driven surgical cutting and fastening instrumentthat may or may not be reused. In the illustrated example, theinstrument 9010 includes a housing 9028 that comprises a handle 9030that is configured to be grasped, manipulated and actuated by theclinician. In the example illustrated in FIG. 30, the housing 9028 isoperably coupled to a shaft assembly 9032 that has a surgical endeffector 9012 configured to perform one or more surgical tasks orprocedures.

The housing 9028 depicted in FIG. 30 is shown in connection with a shaftassembly 9032 that includes an end effector 9012 that comprises asurgical cutting and fastening device that is configured to operablysupport a surgical staple cartridge 9018 therein. The housing 9028 maybe configured for use in connection with shaft assemblies that includeend effectors that are adapted to support different sizes and types ofstaple cartridges, have different shaft lengths, sizes, and types, etc.In addition, the housing 9028 also may be effectively employed with avariety of other shaft assemblies including those assemblies that areconfigured to apply other motions and forms of energy such as, forexample, radio frequency (RF) energy, ultrasonic energy and/or motion toend effector arrangements adapted for use in connection with varioussurgical applications and procedures.

Referring to FIG. 31, a non-limiting form of the end effector 9012 isillustrated. As described above, the end effector 9012 may include theanvil 9014 and the staple cartridge 9018. In this non-limiting example,the anvil 9014 is coupled to an elongate channel 9034. In addition, FIG.31 shows a firing bar 9036, configured to longitudinally translate intothe end effector 9012. A distally projecting end of the firing bar 9036can be attached to an E-beam 9038 that can, among other things, assistin spacing the anvil 9014 from a staple cartridge 9018 positioned in theelongate channel 9034 when the anvil 9014 is in a closed position. TheE-beam 9038 can also include a sharpened cutting member 9040 which canbe used to sever tissue as the E-beam 9038 is advanced distally by thefiring bar 9036. In operation, the E-beam 9038 can also actuate, orfire, the staple cartridge 9018. The staple cartridge 9018 can include aplurality of staples 9042. A wedge sled 9044 is driven distally by theE-beam 9038 to force out the staples 9042 into deforming contact withthe anvil 9012 while a cutting member 9040 of the E-beam 9038 seversclamped tissue.

In one aspect, as illustrated in FIGS. 30-32, a motor can be operablycoupled to the firing bar 9036. The motor can be powered by a powersource such as, for example, a battery 9039. The battery 9039 may supplypower to the motor 9082 to motivate the firing bar 9036 to advance theE-beam 9038 to fire the staples 9042 into tissue captured between theanvil 9014 and the staple cartridge 9018 and/or advance the cuttingmember 9040 to sever the captured tissue. Actuation of the motor 9082can be controlled by a firing trigger 9094 that is pivotally supportedon the handle 9030. The firing trigger 9094 can be depressed by anoperator of the surgical instrument 9010 to activate the motor 9082.

In one instance, the firing trigger 9094 can be depressed or actuatedbetween a plurality of positions each yielding a different output value.For example, actuating the firing trigger 9094 to a first position mayyield a first output value, and actuating the firing trigger 9094 to asecond position after the first position may yield a second output valuegreater than the first output value. In certain instances, the greaterthe firing trigger 9094 is depressed or actuated, the greater the outputvalue. In certain instances, the output is a characteristic of motion ofthe firing bar 9036 and/or the cutting member 9040. In one instance, theoutput can be the speed of the cutting member 9040 during advancement ofthe cutting member 9040 in a firing stroke. In such instance, actuatingthe firing trigger 9094 to a first position may cause the cutting member9040 to travel at a first speed, and actuating the firing trigger 9094to a second position may cause the cutting member 9040 to travel at asecond speed different from the first speed. In certain instances, thegreater the firing trigger 9094 is depressed or actuated, the greaterthe speed of travel of the cutting member 9040.

In the aspect illustrated in FIG. 32, a tracking system 9080 isconfigured to determine the position of the firing trigger 9094. Thetracking system 9080 can include a magnetic element, such as permanentmagnet 9086, for example, which is mounted to an arm 9084 extending fromthe firing trigger 9094. The tracking system 9080 can comprise one ormore sensors, such as a first magnetic field sensor 9088 and a secondmagnetic field sensor 9090, for example, which can be configured totrack the position of the magnet 9086. The sensors 9088 and 9090 cantrack the movement of the magnet 9086 and can be in signal communicationwith a microcontroller such as, for example, the microcontroller 9061(FIG. 36). With data from the first sensor 9088 and/or the second sensor9090, the microcontroller 9061 can determine the position of the magnet9086 along a predefined path and, based on that position, themicrocontroller 9061 can determine an output of the motor 9082. Incertain instances, a motor driver 9092 can be in communication with themicrocontroller 9061, and can be configured to drive the motor 9082 inaccordance with an operator's manual input as detected by the trackingsystem 9080.

In certain instances, the magnetic field sensors can be configured todetect movement of the firing trigger 9094 through a firing strokeinstead of, or in addition to, detecting discrete positions along thefiring stroke. The strength of the magnetic field generated by thepermanent magnet, as detected by the magnetic field sensors, changes asthe permanent magnet 9086 is moved with the firing trigger 9094 throughthe firing stroke. The change in the strength of the magnetic field canbe indicative of a characteristic of motion of the firing trigger 9094,which can detected by a microcontroller as a manual input.

The end effector 9012 may include one or more sensors configured tomeasure one or more parameters or characteristics associated with theend effector 9012 and/or a tissue section captured by the end effector9012. In the example illustrated in FIG. 33, the end effector 9012comprises a first sensor 9020 and a second sensor 9026. In variousexamples, the first sensor 9020 and/or the second sensor 9026 maycomprise, for example, a magnetic sensor such as, for example, amagnetic field sensor, a strain gauge, a pressure sensor, a forcesensor, an inductive sensor such as, for example, an eddy currentsensor, a resistive sensor, a capacitive sensor, an optical sensor,and/or any other suitable sensor for measuring one or more parameters ofthe end effector 9012.

In certain instances, the first sensor 9020 and/or the second sensor9026 may comprise, for example, a magnetic field sensor embedded in thefirst jaw member 9014 and configured to detect a magnetic fieldgenerated by a magnet 9024 embedded in the second jaw member 9016 and/orthe staple cartridge 9018. The strength of the detected magnetic fieldmay correspond to, for example, the thickness and/or fullness of a biteof tissue located between the jaw members 9014, 9016. In certaininstances, the first sensor 9020 and/or the second sensor 9026 maycomprise a strain gauge, such as, for example, a micro-strain gauge,configured to measure the magnitude of the strain in the anvil 9014during a clamped condition. The strain gauge provides an electricalsignal whose amplitude varies with the magnitude of the strain.

In some aspects, one or more sensors of the end effector 9012 such as,for example, the first sensor 9020 and/or the second sensor 9026 maycomprise a pressure sensor configured to detect a pressure generated bythe presence of compressed tissue between the jaw members 9014, 9016. Insome examples, one or more sensors of the end effector 9012 such as, forexample, the first sensor 9020 and/or the second sensor 9026 areconfigured to detect the impedance of a tissue section located betweenthe jaw members 9014, 9016. The detected impedance may be indicative ofthe thickness and/or fullness of tissue located between the jaw members9014, 9016.

In one aspect, one or more of the sensors of the end effector 9012 suchas, for example, the first sensor 9012 is configured to measure the gap9022 between the anvil 9014 and the second jaw member 9016. In certaininstances, the gap 9022 can be representative of the thickness and/orcompressibility of a tissue section clamped between the jaw members9014, 9016. In at least one example, the gap 9022 can be equal, orsubstantially equal, to the thickness of the tissue section clampedbetween the jaw members 9014, 9016. In one example, one or more of thesensors of the end effector 9012 such as, for example, the first sensor9020 is configured to measure one or more forces exerted on the anvil9014 by the second jaw member 9016 and/or tissue clamped between theanvil 9014 and the second jaw member 9016. The forces exerted on theanvil 9014 can be representative of the tissue compression experiencedby the tissue section captured between the jaw members 9014, 9016. Inone embodiment, the gap 9022 between the anvil 9014 and the second jawmember 9016 can be measured by positioning a magnetic field sensor onthe anvil 9014 and positioning a magnet on the second jaw member 9016such that the gap 9022 is proportional to the signal detected by themagnetic field sensor and the signal is proportional to the distancebetween the magnet and the magnetic field sensor. It will be appreciatedthat the location of the magnetic field sensor and the magnet may beswapped such that the magnetic field sensor is positioned on the secondjaw member 9016 and the magnet is placed on the anvil 9014.

One or more of the sensors such as, for example, the first sensor 9020and/or the second sensor 9026 may be measured in real-time during aclamping operation. Real-time measurement allows time based informationto be analyzed, for example, by a processor, and used to select one ormore algorithms and/or look-up tables for the purpose of assessing, inreal-time, a manual input of an operator of the surgical instrument9010. Furthermore, real-time feedback can be provided to the operator toassist the operator in calibrating the manual input to yield a desiredoutput.

FIG. 34 is a logic diagram illustrating one aspect of a process 9046 forassessing, in real-time, a manual input of an operator of the surgicalinstrument 9010 and providing real-time feedback to the operator as tothe adequacy of the manual input. In the example illustrated in FIG. 34,the process starts at step or block 9050 where one or more parameters ofthe end effector 9012 are measured. Next at step 9052, a manual input ofan operator of the surgical instrument 9010 is assessed. In one example,a value representative of the manual input is determined Next at step9054, the determined value is evaluated or assessed for a position,rank, and/or status with respect to a desired zone or range. Themeasurement of the parameters of the end effector 9012 and thedetermined value can be employed to select or determine the position,rank, and/or status associated with the determined value. In a followingstep 9056 of the process 9046, the position, rank, and/or statusassociated with the determined value is reported to the operator of thesurgical instrument 9010. The real-time feedback allows the operator toadjust the manual input until a position, rank, and/or status within thedesired zone or range is achieved. For example, the operator may changethe manual input by increasing or decreasing the manual input whilemonitoring the real-time feedback until the position, rank, and/orstatus associated with a determined value that corresponds to a presentmanual input is within the desired zone or range.

FIG. 35 is a logic diagram illustrating one aspect of a real-timefeedback system 9060 for assessing, in real-time, a manual input 9064 ofan operator of the surgical instrument 9010 and providing to theoperator real-time feedback as to the adequacy of the manual input 9064.With reference to FIGS. 81-86, in the example illustrated in FIG. 35,the real-time feedback system 9060 is comprised of a circuit. Thecircuit includes a microcontroller 9061 comprising a processor 9062. Asensor such as, for example, the sensor 9020 is employed by theprocessor 9062 to measure a parameter of the end effector 9012. Inaddition, the processor 9062 can be configured to determine or receive avalue representative of a manual input 9064 of an operator of thesurgical instrument 9010. The manual input 9064 can be continuouslyassessed by the processor 9062 for as long as the manual input 9064 isbeing provided by the operator. The processor 9062 can be configured tomonitor a value representative of the manual input 9064. Furthermore,the processor 9062 is configured to assign, select, or determine aposition, rank, and/or status for the determined value with respect to adesired zone or range. The measurement of the parameter of the endeffector 9012 and the determined value can be employed by the processor9062 to select or determine the position, rank, and/or status associatedwith the determined value, as described in greater detail below. Achange in the manual input 9064 yields a change in the determined valuewhich, in turn, yields a change in the position, rank, and/or statusassigned to the determined value with respect to the desired zone orrange.

As illustrated in FIG. 35, the real-time feedback system 9060 mayfurther include a feedback indicator 9066 which can be adjusted betweena plurality of positions, ranks, and/or statuses inside and outside adesired zone or range. In one example, the processor 9062 may select afirst position (P1), rank, and/or status that characterizes the manualinput 9064 based on a measurement (M1) of a parameter of the endeffector 9012 and a first determined value (V1) representing a firstmanual input (I1). In certain instances, the first position (P1), rank,and/or status may fall outside the desired zone or range. In suchinstances, the operator may change the manual input 9064 from the firstmanual input (I1) to a second manual input (I2) by increasing ordecreasing the manual input 9064, for example. In response, theprocessor 9062 may adjust the feedback indicator 9066 from the firstposition (P1), rank, and/or status to a second position (P2), rank,and/or status, which characterizes the change to the manual input 9064.The processor 9062 may select the second position (P2), rank, and/orstatus based on the measurement (M1) of the parameter of the endeffector 9012 and a second determined value (V2) representing a secondmanual input (I2). In certain instances, the second position (P2), rank,and/or status may fall inside the desired zone or range. In suchinstances, the operator may maintain the second manual input (I2) for aremainder of a treatment cycle or procedure, for example.

In the aspect illustrated in FIG. 35, the microcontroller 9061 includesa storage medium such as, for example, a memory unit 9068. The memoryunit 9068 may be configured to store correlations between measurementsof one or more parameters of the end effector 9012, values representingmanual inputs, and corresponding positions, ranks, and/or statusescharacterizing the manual input 9064 with respect to a desired zone orrange. In one example, the memory unit 9068 may store the correlationbetween the measurement (M1), the first determined value (V1), and thefirst manual input (I1), and the correlation between the measurement(M1), the second determined value (V2), and the second manual input(I2). In one example, the memory unit 9068 may store an algorism, anequation, or a look-up table for determining correlations betweenmeasurements of one or more parameters of the end effector 9012, valuesrepresenting manual inputs, and corresponding positions, ranks, orstatuses with respect to a desired zone or range. The processor 9062 mayemploy such algorism, equation, and/or look-up table to characterize amanual input 9064 provided by an operator of the surgical instrument9010 and provide feedback to the operator as to the adequacy of themanual input 9064.

FIG. 36 is a logic diagram illustrating one aspect of a real-timefeedback system 9070. The system 9070 is similar in many respects to thesystem 9060. For example, like the system 9060, the system 9070 isconfigured for assessing, in real-time, a manual input of an operator ofthe surgical instrument 9010 and providing to the operator real-timefeedback as to the adequacy of the manual input. Furthermore, like thesystem 9060, the system 9070 is comprised of a circuit that may includethe microcontroller 9061.

In the aspect illustrated in FIG. 36, a strain gauge 9072, such as, forexample, a micro-strain gauge, is configured to measure one or moreparameters of the end effector 9012, such as, for example, the amplitudeof the strain exerted on the anvil 9014 during a clamping operation,which can be indicative of the tissue compression. The measured strainis converted to a digital signal and provided to the processor 9062. Aload sensor 9074 can measure the force to advance the cutting member9040 to cut tissue captured between the anvil 9014 and the staplecartridge 9018. Alternatively, a current sensor (not shown) can beemployed to measure the current drawn by the motor 9082. The forcerequired to advance the firing bar 9036 can correspond to the currentdrawn by the motor 9082, for example. The measured force is converted toa digital signal and provided to the processor 9062. A magnetic fieldsensor 9076 can be employed to measure the thickness of the capturedtissue, as described above. The measurement of the magnetic field sensor9076 is also converted to a digital signal and provided to the processor9062.

In the aspect illustrated in FIG. 36, the system 9070 further includesthe tracking system 9080 which can be configured to determine theposition of the firing trigger 9094 (FIG. 32). As described above, thefiring trigger 9094 can be depressed or actuated by moving the firingtrigger 9094 between a plurality of positions, each corresponding to oneof a plurality of values of a characteristic of motion of the firing bar9036 and/or the cutting member 9040 during a firing stroke. As describeabove, a characteristic of motion can be a speed of advancement of thefiring bar 9036 and/or the cutting member 9040 during the firing stroke.In certain instances, a motor driver 9092 can be in communication withthe microcontroller 9061, and can be configured to drive the motor 9082in accordance with an operator's manual input as detected by thetracking system 9080.

Further to the above, the system 9070 may include a feedback indicator9066. In one aspect, the feedback indicator 9066 can be disposed in thehandle 9030. Alternatively, the feedback indicator can be disposed inthe shaft assembly 9032, for example. In any event, the microcontroller9061 may employ the feedback indicator 9066 to provide feedback to anoperator of the surgical instrument 9010 with regard to the adequacy ofa manual input such as, for example, a selected position of the firingtrigger 9094. To do so, the microcontroller 9061 may assess the selectedposition of the firing trigger 9094 and/or the corresponding value ofthe speed of the firing bar 9036 and/or the cutting member 9040. Themeasurements of the tissue compression, the tissue thickness, and/or theforce required to advance the firing bar 9036, as respectively measuredby the sensors 9072, 9074, and 9076, can be used by the microcontroller9061 to characterize the selected position of the firing trigger 9094and/or the corresponding value of the speed of the firing bar 9036and/or the cutting member 9040. In one instance, the memory 9068 maystore an algorism, an equation, and/or a look-up table which can beemployed by the microcontroller 9061 in the assessment. In one example,the measurements of the sensors 9072, 9074, and/or 9076 can be used toselect or determine a position, rank, and/or a status that characterizesthe selected position of the firing trigger 9094 and/or thecorresponding value of the speed of the firing bar 9036 and/or thecutting member 9040. The determined position, rank, and/or status can becommunicated to the operator via the feedback indicator 9066.

The reader will appreciate that an optimal speed of the firing bar 9036and/or the cutting member 9040 during a firing stroke can depend onseveral parameters of the end effector 9012 such as, for example, thethickness of the tissue captured by the end effector 9012, the tissuecompression, and/or the force required to advance the firing bar 9036and, in turn, the cutting member 9040. As such, measurements of theseparameters can be leveraged by the microcontroller 9061 in assessingwhether a current speed of advancement of the cutting member 9040through the captured tissue is within an optimal zone or range.

In one aspect, as illustrated in FIGS. 37-39, the feedback indicator9066 includes a dial 9096 and a pointer 9098 movable between a pluralitypositions relative to the dial 9096. The dial 9096 is divided to definean optimal zone, a so-called “TOO FAST” zone, and a so-called “TOO SLOW”zone. The pointer 9098 can be set to one of a plurality of positionswithin the three zones. In one example, as illustrated in FIG. 37, thepointer is set to a position in the “TOO SLOW” zone to alert theoperator that a selected speed of advancement of the cutting member 9040through the tissue captured by the end effector 9012 is below an optimalor a desired zone. As described above, such a characterization of theselected speed can be performed by the microcontroller 9061 based on oneor more measurements of one or more parameters of the end effector 9012.In another example, perhaps after the operator increases the speed ofthe cutting member 9040 in response to the previous alert, the pointeris moved to a new position in the “TOO FAST” zone, as illustrated inFIG. 38, to alert the operator that a newly selected speed of thecutting member 9040 exceeds the optimal zone. The operator may continueto adjust the speed of the cutting member 9040 by adjusting the positionof the firing trigger 9094 until the pointer lands in the optimal zone,as illustrated in FIG. 39. At such point, the operator may maintain thecurrent position of the firing trigger 9094 for the remainder of thefiring stroke.

In certain instances, the dial 9096 and the pointer 9098 can be replacedwith a digital indicator. In one example, the digital indicator includesa screen that illustrates the above-identified three zones. A digitalpointer can be transitioned between a plurality of positions on thescreen to provide feedback to the operator in accordance with thepresent disclosure. In certain instances, as illustrated in FIGS. 40-42,the feedback indicator 9066 includes a plurality of zones with a middlezone indicating an optimal or ideal speed of the cutting member 9040. Inthe example illustrated in FIG. 40, nine zones are illustrated. However,in alternative examples, the feedback indicator 9066 may include five orseven zones, for example. As illustrated in FIG. 40, the plurality ofzones can be color coded. For example, the middle zone can be in green.The first two zones to the right and the first two zones to the left ofthe middle zone can be in yellow. The remaining zones can be in red. Incertain instances, as illustrated in FIG. 40, the nine zones can benumbered with the numbers −4, −3, −2, 0, +1, +2, +3, and +4,respectively from left to right. In at least one example, the pluralityof zones can be numbered and color coded.

In any event, as illustrated in FIGS. 41-44, a pointer 9100 is movablebetween a plurality of positions to point to one of the nine zones. Anoperator of the surgical instrument 9010 may squeeze the firing trigger9094 while monitoring the position of the pointer 9100. Depending on theposition taken by the pointer 9100, the operator may reduce or increasethe pressure on the trigger 9094 until the pointer 9100 rests in themiddle or optimal zone. At such point, the operator may maintain thecurrent pressure on the firing trigger 9094 for the remainder of thefiring stroke. In certain instances, as illustrated in FIG. 45, thefeedback indicator 9066 may alert the operator that the firing stroke iscompleted.

In certain instances, as described above, the jaw members 9014, 9016include electrically conductive layers configured to deliver energy totissue captured between the jaw members 9014, 9016. An energy trigger oractuator can be moved or depressed between a plurality of positions orsettings, in a similar manner to the firing trigger 9094, to deliver theenergy to the tissue. The level or intensity of the energy delivered tothe tissue may depend on the selected position. For example, depressingthe energy trigger to a first position may yield a first energy level,and depressing the energy trigger to a second position, different fromthe first position, may yield a second energy level different from thefirst energy level. A tracking system, like the tracking system 9080,can track the position of the energy trigger and report such manualinput to the microcontroller 9061. Alternatively, the resulting energylevel can be monitored and reported to the microcontroller 9061. Acurrent sensor or a voltage sensor, for example, can be employed tomonitor the resulting energy level.

In any event, the microcontroller 9061 may be configured to characterizethe selected position of the energy trigger and/or the resulting energylevel in view of one or more measured parameters of the end effector9012 and/or one or more characteristics of the captured tissue such astissue thickness, tissue compression, and/or tissue impedance. One ormore sensors can be employed to obtain measurements of one or parametersof the end effector and/or one or more characteristics of the capturedtissue, which can be reported in real-time to the microcontroller 9061.In response, the microcontroller 9061 may characterize the selectedposition of the energy trigger and/or the resulting energy level byselecting or determining a position, rank, and/or status of the selectedposition of the energy trigger and/or the resulting energy level withrespect to a desired zone or range. As described above, the memory unit9068 can include an algorism, equation, and/or look-up table fordetermining the position, rank, and/or status of the selected positionof the energy trigger and/or the resulting energy level. Furthermore,the position, rank, and/or status can be reported to the operator of theenergy trigger in real-time via a feedback indicator, similar to thefeedback indicator 9066, for example.

One of the advantages of the feedback methods and systems of the presentdisclosure is that they reduce the number of variables that an operatorneed to consider while providing a manual input such as, for example,actuating the firing trigger 9094. As such, the operator is relievedfrom having to manually consider each of the measured parameters of theend effector 9012 to estimate the adequacy of a manual input and/or anoutput value resulting from the manual input such as the speed of thecutting member 9040. Instead, a current manual input and/or an outputvalue of the manual input can be automatically characterized by themicrocontroller 9061 in view of all the measured parameters of the endeffector 9012 to provide the operator with one consolidated real-timefeedback through the feedback indicator 9066. The operator may thenfocus on such feedback and adjust the manual input to achieve an optimalresult.

Further to the above, the feedback methods and systems of the presentdisclosure would give the operator a repeatable relative measure tojudge the adequacy of a manual input. In addition, the operator coulddecide for themselves how far beyond an optimal zone, with respect tosuch relative measure, they are willing to reach comfortably to achievea good outcome. Furthermore, the feedback methods and systems of thepresent disclosure would also give the operator a warning if the firingwas out of the ordinary so that additional caution may be exercised.Furthermore, by focusing on the one consolidated real-time feedback, anoperator can learn quicker the best way to fire a surgical instrument.

The present disclosure will now be described in connection with variousexamples and combinations of such examples as set forth hereinbelow.

1. One example provides a surgical instrument, comprising: an endeffector, comprising: a first jaw; and a second jaw, wherein the firstjaw and the second jaw cooperate to capture tissue therebetween; afiring member movable to cut the captured tissue; an actuator actuatablebetween a plurality of settings, wherein the plurality of settingsdefine a plurality of output values of a characteristic of motion of thefiring member; and a real-time feedback system, comprising: at least onesensor configured to assess at least one parameter of the end effector;a zone indicator adjustable between a plurality of positions inside andoutside a desired zone; and a circuit configured to: receive at leastone sensor input from the at least one sensor, wherein the at least onesensor input defines at least one measurement of the at least oneparameter of the end effector; select one of the plurality of positionsbased upon the at least one measurement of the at least one parameter ofthe end effector, wherein the selected one of the plurality of positionsrepresents a status of a current output value of the characteristic ofmotion of the firing member; and adjust the zone indicator to theselected one of the plurality of positions.

2. Another example provides the surgical instrument of example 1,wherein the at least one parameter comprises a distance between thefirst jaw and the second jaw.

3. Another example provides the surgical instrument of examples 1 or 2,wherein the at least one parameter comprises a compression level of thecaptured tissue.

4. Another example provides the surgical instrument of any one ofexamples 1-3, wherein the at least one parameter comprises a forcerequired to advance the firing member.

5. Another example provides the surgical instrument of any one ofexamples 1-4, wherein the plurality of positions comprises at least twopositions inside the desired zone.

6. Another example provides the surgical instrument of any one ofexamples 1-5, wherein the plurality of positions comprises at least oneposition inside the desired zone and at least one position outside thedesired zone.

7. Another example provides the surgical instrument of any one ofexamples 1-6, wherein the characteristic of motion is a velocity of thefiring member.

8. Another example provides the surgical instrument of any one ofexamples 1-7, further comprising a tacking system configured todetermine a current setting of the actuator.

9. Yet another provides a surgical instrument, comprising: an endeffector configured to capture tissue; and a real time feedback system,comprising: at least one sensor configured to assess at least oneparameter of the end effector a zone indicator adjustable between aplurality of positions inside and outside a desired zone; and a circuitconfigured to: receive at least one sensor input from the at least onesensor, wherein the at least one sensor input defines at least onemeasurement of the at least one parameter of the end effector; assess amanual input; select one of the plurality of positions based upon the atleast one measurement of the at least one parameter of the end effector,wherein the selected one of the plurality of positions characterizes themanual input with respect to the desired zone; and adjust the zoneindicator to the selected one of the plurality of positions.

10. Another example provides the surgical instrument of example 9,wherein the at least one parameter comprises a distance between thefirst jaw and the second jaw.

11. Another example provides the surgical instrument of examples 9 or10, wherein the at least one parameter comprises a compression level ofthe captured tissue.

12. Another example provides the surgical instrument of any one ofexamples 9-11, wherein the at least one parameter comprises a forcerequired to advance the firing member.

13. Another example provides the surgical instrument of any one ofexamples 9-12, wherein the plurality of positions comprises at least twopositions inside the desired zone.

14. Another example provides the surgical instrument of any one ofexamples 9-13, wherein the plurality of positions comprises at least oneposition inside the desired zone and at least one position outside thedesired zone.

15. Another example provides the surgical instrument of any one ofexamples 9-14, wherein the step of assessing the manual input comprisesdetermining a value defined by the manual input.

16. Yet another example provides a surgical instrument, comprising: anend effector, comprising: a first jaw; and a second jaw, wherein thefirst jaw and the second jaw cooperate to capture tissue therebetween; afiring member movable to cut the captured tissue; an actuator actuatablebetween a plurality of settings; and a real time feedback system,comprising: at least one sensor configured to assess at least oneparameter of the end effector; a processor; and a memory that storesprogram instructions, which when executed from the memory cause theprocessor to: receive at least one sensor input from the at least onesensor, wherein the at least one sensor input defines at least onemeasurement of the at least one parameter of the end effector determinea value representing a current setting of the plurality of settings ofthe actuator; assign a rank to the value with respect to a desiredrange, wherein the rank is based upon the value and the at least onemeasurement of the at least one parameter of the end effector; andreport the rank.

17. Another example provides the surgical instrument of example 16,wherein the at least one parameter comprises a distance between thefirst jaw and the second jaw.

18. Another example provides the surgical instrument of examples 16 or17, wherein the at least one parameter comprises a compression level ofthe captured tissue.

19. Another example provides the surgical instrument of any one ofexamples 16-18, wherein the at least one parameter comprises a forcerequired to advance the firing member.

20. Another example provides the surgical instrument of any one ofexamples 16-19, wherein the memory stores at least one of an algorism,an equation, or a look-up table accessible to by the processor todetermine rank.

In accordance with various examples, the surgical instruments describedherein may comprise one or more processors (e.g., microprocessor,microcontroller) coupled to various sensors. In addition, to theprocessor(s), a storage (having operating logic) and communicationinterface, are coupled to each other.

As described earlier, the sensors may be configured to detect andcollect data associated with the surgical device. The processorprocesses the sensor data received from the sensor(s).

The processor may be configured to execute the operating logic. Theprocessor may be any one of a number of single or multi-core processorsknown in the art. The storage may comprise volatile and non-volatilestorage media configured to store persistent and temporal (working) copyof the operating logic.

In various aspects, the operating logic may be configured to perform theinitial processing, and transmit the data to the computer hosting theapplication to determine and generate instructions. For these examples,the operating logic may be further configured to receive informationfrom and provide feedback to a hosting computer. In alternate examples,the operating logic may be configured to assume a larger role inreceiving information and determining the feedback. In either case,whether determined on its own or responsive to instructions from ahosting computer, the operating logic may be further configured tocontrol and provide feedback to the user.

In various aspects, the operating logic may be implemented ininstructions supported by the instruction set architecture (ISA) of theprocessor, or in higher level languages and compiled into the supportedISA. The operating logic may comprise one or more logic units ormodules. The operating logic may be implemented in an object orientedmanner. The operating logic may be configured to be executed in amulti-tasking and/or multi-thread manner. In other examples, theoperating logic may be implemented in hardware such as a gate array.

In various aspects, the communication interface may be configured tofacilitate communication between a peripheral device and the computingsystem. The communication may include transmission of the collectedbiometric data associated with position, posture, and/or movement dataof the user's body part(s) to a hosting computer, and transmission ofdata associated with the tactile feedback from the host computer to theperipheral device. In various examples, the communication interface maybe a wired or a wireless communication interface. An example of a wiredcommunication interface may include, but is not limited to, a UniversalSerial Bus (USB) interface. An example of a wireless communicationinterface may include, but is not limited to, a Bluetooth interface.

For various aspects, the processor may be packaged together with theoperating logic. In various examples, the processor may be packagedtogether with the operating logic to form a SiP. In various examples,the processor may be integrated on the same die with the operatinglogic. In various examples, the processor may be packaged together withthe operating logic to form a System on Chip (SoC).

Various aspects may be described herein in the general context ofcomputer executable instructions, such as software, program modules,and/or engines being executed by a processor. Generally, software,program modules, and/or engines include any software element arranged toperform particular operations or implement particular abstract datatypes. Software, program modules, and/or engines can include routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, program modules, and/or enginescomponents and techniques may be stored on and/or transmitted acrosssome form of computer-readable media. In this regard, computer-readablemedia can be any available medium or media useable to store informationand accessible by a computing device. Some examples also may bepracticed in distributed computing environments where operations areperformed by one or more remote processing devices that are linkedthrough a communications network. In a distributed computingenvironment, software, program modules, and/or engines may be located inboth local and remote computer storage media including memory storagedevices. A memory such as a random access memory (RAM) or other dynamicstorage device may be employed for storing information and instructionsto be executed by the processor. The memory also may be used for storingtemporary variables or other intermediate information during executionof instructions to be executed by the processor.

Although some aspects may be illustrated and described as comprisingfunctional components, software, engines, and/or modules performingvarious operations, it can be appreciated that such components ormodules may be implemented by one or more hardware components, softwarecomponents, and/or combination thereof. The functional components,software, engines, and/or modules may be implemented, for example, bylogic (e.g., instructions, data, and/or code) to be executed by a logicdevice (e.g., processor). Such logic may be stored internally orexternally to a logic device on one or more types of computer-readablestorage media. In other examples, the functional components such assoftware, engines, and/or modules may be implemented by hardwareelements that may include processors, microprocessors, circuits, circuitelements (e.g., transistors, resistors, capacitors, inductors, and soforth), integrated circuits, ASICs, PLDs, DSPs, FPGAs, logic gates,registers, semiconductor device, chips, microchips, chip sets, and soforth.

Examples of software, engines, and/or modules may include softwarecomponents, programs, applications, computer programs, applicationprograms, system programs, machine programs, operating system software,middleware, firmware, software modules, routines, subroutines,functions, methods, procedures, software interfaces, application programinterfaces (API), instruction sets, computing code, computer code, codesegments, computer code segments, words, values, symbols, or anycombination thereof. Determining whether one example is implementedusing hardware elements and/or software elements may vary in accordancewith any number of factors, such as desired computational rate, powerlevels, heat tolerances, processing cycle budget, input data rates,output data rates, memory resources, data bus speeds and other design orperformance constraints.

One or more of the modules described herein may comprise one or moreembedded applications implemented as firmware, software, hardware, orany combination thereof. One or more of the modules described herein maycomprise various executable modules such as software, programs, data,drivers, application APIs, and so forth. The firmware may be stored in amemory of the controller and/or the controller which may comprise anonvolatile memory (NVM), such as in bit-masked ROM or flash memory. Invarious implementations, storing the firmware in ROM may preserve flashmemory. The NVM may comprise other types of memory including, forexample, programmable ROM (PROM), erasable programmable ROM (EPROM),EEPROM, or battery backed RAM such as dynamic RAM (DRAM),Double-Data-Rate DRAM (DDRAM), and/or synchronous DRAM (SDRAM).

In some cases, various aspects may be implemented as an article ofmanufacture. The article of manufacture may include a computer readablestorage medium arranged to store logic, instructions and/or data forperforming various operations of one or more examples. In variousexamples, for example, the article of manufacture may comprise amagnetic disk, optical disk, flash memory or firmware containingcomputer program instructions suitable for execution by a generalpurpose processor or application specific processor. The examples,however, are not limited in this context.

The functions of the various functional elements, logical blocks,modules, and circuits elements described in connection with the examplesdisclosed herein may be implemented in the general context of computerexecutable instructions, such as software, control modules, logic,and/or logic modules executed by the processing unit. Generally,software, control modules, logic, and/or logic modules comprise anysoftware element arranged to perform particular operations. Software,control modules, logic, and/or logic modules can comprise routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, control modules, logic, and/or logicmodules and techniques may be stored on and/or transmitted across someform of computer-readable media. In this regard, computer-readable mediacan be any available medium or media useable to store information andaccessible by a computing device. Some examples also may be practiced indistributed computing environments where operations are performed by oneor more remote processing devices that are linked through acommunications network. In a distributed computing environment,software, control modules, logic, and/or logic modules may be located inboth local and remote computer storage media including memory storagedevices.

Additionally, it is to be appreciated that the aspects described hereinillustrate example implementations, and that the functional elements,logical blocks, modules, and circuits elements may be implemented invarious other ways which are consistent with the described examples.Furthermore, the operations performed by such functional elements,logical blocks, modules, and circuits elements may be combined and/orseparated for a given implementation and may be performed by a greaternumber or fewer number of components or modules. As will be apparent tothose of skill in the art upon reading the present disclosure, each ofthe individual examples described and illustrated herein has discretecomponents and features which may be readily separated from or combinedwith the features of any of the other several aspects without departingfrom the scope of the present disclosure. Any recited method can becarried out in the order of events recited or in any other order whichis logically possible.

It is worthy to note that any reference to “one example” or “an example”means that a particular feature, structure, or characteristic describedin connection with the example is comprised in at least one example. Theappearances of the phrase “in one example” or “in one aspect” in thespecification are not necessarily all referring to the same example.

Unless specifically stated otherwise, it may be appreciated that termssuch as “processing,” “computing,” “calculating,” “determining,” or thelike, refer to the action and/or processes of a computer or computingsystem, or similar electronic computing device, such as a generalpurpose processor, a DSP, ASIC, FPGA or other programmable logic device,discrete gate or transistor logic, discrete hardware components, or anycombination thereof designed to perform the functions described hereinthat manipulates and/or transforms data represented as physicalquantities (e.g., electronic) within registers and/or memories intoother data similarly represented as physical quantities within thememories, registers or other such information storage, transmission ordisplay devices.

It is worthy to note that some aspects may be described using theexpression “coupled” and “connected” along with their derivatives. Theseterms are not intended as synonyms for each other. For example, someaspects may be described using the terms “connected” and/or “coupled” toindicate that two or more elements are in direct physical or electricalcontact with each other. The term “coupled,” however, also may mean thattwo or more elements are not in direct contact with each other, but yetstill co-operate or interact with each other. With respect to softwareelements, for example, the term “coupled” may refer to interfaces,message interfaces, API, exchanging messages, and so forth.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

The present disclosure applies to conventional endoscopic and opensurgical instrumentation as well as application in robotic-assistedsurgery.

Aspects of the devices disclosed herein can be designed to be disposedof after a single use, or they can be designed to be used multipletimes. Examples may, in either or both cases, be reconditioned for reuseafter at least one use. Reconditioning may include any combination ofthe steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, examples of the device may be disassembled, and any numberof the particular pieces or parts of the device may be selectivelyreplaced or removed in any combination. Upon cleaning and/or replacementof particular parts, examples of the device may be reassembled forsubsequent use either at a reconditioning facility, or by a surgicalteam immediately prior to a surgical procedure. Those skilled in the artwill appreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, aspects described herein may be processed beforesurgery. First, a new or used instrument may be obtained and whennecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device also may be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, plasma peroxide, or steam.

One skilled in the art will recognize that the herein describedcomponents (e.g., operations), devices, objects, and the discussionaccompanying them are used as examples for the sake of conceptualclarity and that various configuration modifications are contemplated.Consequently, as used herein, the specific exemplars set forth and theaccompanying discussion are intended to be representative of their moregeneral classes. In general, use of any specific exemplar is intended tobe representative of its class, and the non-inclusion of specificcomponents (e.g., operations), devices, and objects should not be takenlimiting.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations are not expressly set forth herein for sakeof clarity.

The herein described subject matter sometimes illustrates differentcomponents contained within, or connected with, different othercomponents. It is to be understood that such depicted architectures aremerely examples and that in fact many other architectures may beimplemented which achieve the same functionality. In a conceptual sense,any arrangement of components to achieve the same functionality iseffectively “associated” such that the desired functionality isachieved. Hence, any two components herein combined to achieve aparticular functionality can be seen as “associated with” each othersuch that the desired functionality is achieved, irrespective ofarchitectures or intermedial components. Likewise, any two components soassociated can also be viewed as being “operably connected,” or“operably coupled,” to each other to achieve the desired functionality,and any two components capable of being so associated can also be viewedas being “operably couplable,” to each other to achieve the desiredfunctionality. Specific examples of operably couplable include but arenot limited to physically matable and/or physically interactingcomponents, and/or wirelessly interactable, and/or wirelesslyinteracting components, and/or logically interacting, and/or logicallyinteractable components.

Some aspects may be described using the expression “coupled” and“connected” along with their derivatives. It should be understood thatthese terms are not intended as synonyms for each other. For example,some aspects may be described using the term “connected” to indicatethat two or more elements are in direct physical or electrical contactwith each other. In another example, some aspects may be described usingthe term “coupled” to indicate that two or more elements are in directphysical or electrical contact. The term “coupled,” however, also maymean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other.

In some instances, one or more components may be referred to herein as“configured to,” “configurable to,” “operable/operative to,”“adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Thoseskilled in the art will recognize that “configured to” can generallyencompass active-state components and/or inactive-state componentsand/or standby-state components, unless context requires otherwise.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be apparent to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from the subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true scope of the subject matter described herein. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that when aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations.

In addition, even when a specific number of an introduced claimrecitation is explicitly recited, those skilled in the art willrecognize that such recitation should typically be interpreted to meanat least the recited number (e.g., the bare recitation of “tworecitations,” without other modifiers, typically means at least tworecitations, or two or more recitations). Furthermore, in thoseinstances where a convention analogous to “at least one of A, B, and C,etc.” is used, in general such a construction is intended in the senseone having skill in the art would understand the convention (e.g., “asystem having at least one of A, B, and C” would include but not belimited to systems that have A alone, B alone, C alone, A and Btogether, A and C together, B and C together, and/or A, B, and Ctogether, etc.). In those instances where a convention analogous to “atleast one of A, B, or C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, or C” wouldinclude but not be limited to systems that have A alone, B alone, Calone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). It will be further understood by those withinthe art that typically a disjunctive word and/or phrase presenting twoor more alternative terms, whether in the description, claims, ordrawings, should be understood to contemplate the possibilities ofincluding one of the terms, either of the terms, or both terms unlesscontext dictates otherwise. For example, the phrase “A or B” will betypically understood to include the possibilities of “A” or “B” or “Aand B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flows are presented in asequence(s), it should be understood that the various operations may beperformed in other orders than those which are illustrated, or may beperformed concurrently. Examples of such alternate orderings may includeoverlapping, interleaved, interrupted, reordered, incremental,preparatory, supplemental, simultaneous, reverse, or other variantorderings, unless context dictates otherwise. Furthermore, terms like“responsive to,” “related to,” or other past-tense adjectives aregenerally not intended to exclude such variants, unless context dictatesotherwise.

In summary, numerous benefits have been described which result fromemploying the concepts described herein. The foregoing disclosure hasbeen presented for purposes of illustration and description. It is notintended to be exhaustive or limiting to the precise form disclosed.Modifications or variations are possible in light of the aboveteachings. The one or more examples were chosen and described in orderto illustrate principles and practical application to thereby enable oneof ordinary skill in the art to utilize the various examples and withvarious modifications as are suited to the particular use contemplated.It is intended that the claims submitted herewith define the overallscope.

What is claimed is:
 1. A surgical instrument, comprising: an endeffector, comprising: a first jaw; and a second jaw, wherein the firstjaw and the second jaw cooperate to capture tissue therebetween; afiring member movable to cut the captured tissue; an actuator actuatablebetween a plurality of settings, wherein the plurality of settingsdefine a plurality of output values of a characteristic of motion of thefiring member; and a real-time feedback system, comprising: at least onesensor configured to assess at least one parameter of the end effector;a zone indicator adjustable between a plurality of positions inside andoutside a desired zone; and a circuit configured to: receive at leastone sensor input from the at least one sensor, wherein the at least onesensor input defines at least one measurement of the at least oneparameter of the end effector; select one of the plurality of positionsbased upon the at least one measurement of the at least one parameter ofthe end effector, wherein the selected one of the plurality of positionsrepresents a status of a current output value of the characteristic ofmotion of the firing member; and adjust the zone indicator to theselected one of the plurality of positions.
 2. The surgical instrumentof claim 1, wherein the at least one parameter comprises a distancebetween the first jaw and the second jaw.
 3. The surgical instrument ofclaim 1, wherein the at least one parameter comprises a compressionlevel of the captured tissue.
 4. The surgical instrument of claim 1,wherein the at least one parameter comprises a force required to advancethe firing member.
 5. The surgical instrument of claim 1, wherein theplurality of positions comprises at least two positions inside thedesired zone.
 6. The surgical instrument of claim 1, wherein theplurality of positions comprises at least one position inside thedesired zone and at least one position outside the desired zone.
 7. Thesurgical instrument of claim 1, wherein the characteristic of motion isa velocity of the firing member.
 8. The surgical instrument of claim 1,further comprising a tacking system configured to determine a currentsetting of the actuator.
 9. A surgical instrument, comprising: an endeffector configured to capture tissue; and a real time feedback system,comprising: at least one sensor configured to assess at least oneparameter of the end effector a zone indicator adjustable between aplurality of positions inside and outside a desired zone; and a circuitconfigured to: receive at least one sensor input from the at least onesensor, wherein the at least one sensor input defines at least onemeasurement of the at least one parameter of the end effector; assess amanual input; select one of the plurality of positions based upon the atleast one measurement of the at least one parameter of the end effector,wherein the selected one of the plurality of positions characterizes themanual input with respect to the desired zone; and adjust the zoneindicator to the selected one of the plurality of positions.
 10. Thesurgical instrument of claim 9, wherein the at least one parametercomprises a distance between the first jaw and the second jaw.
 11. Thesurgical instrument of claim 9, wherein the at least one parametercomprises a compression level of the captured tissue.
 12. The surgicalinstrument of claim 9, wherein the at least one parameter comprises aforce required to advance the firing member.
 13. The surgical instrumentof claim 9, wherein the plurality of positions comprises at least twopositions inside the desired zone.
 14. The surgical instrument of claim9, wherein the plurality of positions comprises at least one positioninside the desired zone and at least one position outside the desiredzone.
 15. The surgical instrument of claim 9, wherein the step ofassessing the manual input comprises determining a value defined by themanual input.
 16. A surgical instrument, comprising: an end effector,comprising: a first jaw; and a second jaw, wherein the first jaw and thesecond jaw cooperate to capture tissue therebetween; a firing membermovable to cut the captured tissue; an actuator actuatable between aplurality of settings; and a real time feedback system, comprising: atleast one sensor configured to assess at least one parameter of the endeffector; a processor; and a memory that stores program instructions,which when executed from the memory cause the processor to: receive atleast one sensor input from the at least one sensor, wherein the atleast one sensor input defines at least one measurement of the at leastone parameter of the end effector; determine a value representing acurrent setting of the plurality of settings of the actuator; assign arank to the value with respect to a desired range, wherein the rank isbased upon the value and the at least one measurement of the at leastone parameter of the end effector; and report the rank.
 17. The surgicalinstrument of claim 16, wherein the at least one parameter comprises adistance between the first jaw and the second jaw.
 18. The surgicalinstrument of claim 16, wherein the at least one parameter comprises acompression level of the captured tissue.
 19. The surgical instrument ofclaim 16, wherein the at least one parameter comprises a force requiredto advance the firing member.
 20. The surgical instrument of claim 16,wherein the memory stores at least one of an algorism, an equation, or alook-up table accessible to by the processor to determine rank.